7/51, 7/71, 12/56

OPERATION AND MAINTENANCE MANUAL

This manual contains

important safety information
and must be made available to
personnel who operate and
maintain this machine.
7/51 SERIAL No : 443500 −>

7/71, 12/56 SERIAL No : 522700 −>

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
C.C.N. : 23344104 GB
in nature, and is not meant to suggest a current affiliation between REV :A
Ingersoll-Rand Company and Doosan Company or the products of
either. DATE : SEPTEMBER 2008
Revised (10-12)
 Machine models represented in this manual may be used in various locations world−wide. Machines sold and shipped
into European Union Territories require that the machine display the EC Mark and conform to various directives. In
such cases, the design specification of this machine has been certified as complying with EC directives. Any
modification to any part is absolutely prohibited and would result in the CE Certification and marking being rendered
invalid. A declaration of that conformity follows:

DECLARATION OF CONFORMITY WITH EC DIRECTIVES

98/37/EC, 93/68/EEC, 89/336/EEC, 2000/14/EC

We
Doosan International USA, Inc Doosan Trading Limited
1293 Glenway Drive Represented in EC by: 170−175 Lake View Road
Statesville, North Carolina 28625−9218 Airside Business Park
Swords
County Dublin
Ireland
Declare that, under our sole responsibility for manufacture and supply, the product(s)

7/51, 7/71, 12/56

to which this declaration relates, is (are) in conformity with the provisions of the above
directives using the following principal standards

EN29001, EN60204−1, EN1012−1, PN8NTC2

Issued at Statesville on
01−09−2008

________________________________

Ric Lunsford
Manager of quality control

CONFORMITY WITH NOISE DIRECTIVE 2000/14/EC

Doosan International USA Inc declare that the following Portable Compressors have been manufactured in
conformity with the directive as shown
Machine Serial number Mean measured Guaranteed
Directive Notified body
Type kW range value Level
2000/14/EC 7/51 50.2 443500− 449999 97 LWA 98 LWA A V Technology
Annex VI 7/71 Stockport
p UK
P tI
Part 59 2
59.2 522700− 539999 98 LWA 99 LWA N 1067
Nr
12/56

________________________________

Issued at . . . . . . . . . . . Dobris Tomas Hibs

SEPTEMBER 2008 Engineering manager

EC Pressure Equipment Directive and Related Regulations

We declare that this product has been assessed according to the Pressure Equipment Directive (97/23/EC) and, in
accordance with the terms of this Directive, has been excluded from the scope of this Directive.
It may carry ”CE” marking in compliance with other applicable EC Directives.
 CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to

the State of California to cause cancer, birth defects, and other
reproductive harm.
1 CONTENTS & ABBREVIATIONS

1 CONTENTS ABBREVIATIONS & SYMBOLS

2 FOREWORD #### Contact Ingersoll−Rand for serial number

−>#### Up to Serial No.
3 WARRANTY ####−> From Serial No.

9 DECALS * Not illustrated

† Option
15 NOISE EMISSION
AR As required

19 MAINTENANCE RECORD FOR NOISE BR Brazil

EMISSION CONTROL AND EXTENDED CN China
WARRANTY
DE Germany
20 SAFETY
DK Denmark
23 GENERAL INFORMATION ES Spain
Dimensions FI Finland
Data
FR France
27 OPERATING INSTRUCTIONS GB Great Britain (English)
Commissioning
Prior to starting HA High ambient machine
Starting IT Italy
Stopping
Emergency stopping NL Holland
Re−starting NO Norway
Monitoring during operation
Decommissioning PT Portugal
SE Sweden
33 MAINTENANCE
US United States
Routine maintenance
Lubrication F.H.R.G. Fixed height running gear
Speed & pressure regulation
Torque settings table V.H.R.G. Variable height running gear
Compressor lubrication SECU Small electronic control unit

45 MACHINE SYSTEMS
Electrical system
Piping & instrumentation system

54 FAULT FINDING

57 OPTIONS

Lubricator.
Safety.
General Information.
Operating Instructions.
Maintenance.
Fault Finding.

Generator.
Safety.
General Information.
Operating Instructions.
Maintenance.
Fault Finding.

65 ENGINE INSTRUCTION MANUAL

7/51, 7/71, 12/56


The contents of this manual are considered to be proprietary and
confidential to Ingersoll−Rand and should not be reproduced without
the prior written permission of Ingersoll−Rand.
Nothing contained in this document is intended to extend any
promise, warranty or representation, expressed or implied, regarding
the Ingersoll−Rand products described herein. Any such warranties or
other terms and conditions of sale of products shall be in accordance
with the standard terms and conditions of sale for such products, which
are available upon request.
This manual contains instructions and technical data to cover all
routine operation and scheduled maintenance tasks by operation and
maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorised Ingersoll−Rand service
department.
The design specification of this machine has been certified as
complying with EC directives. As a result:
(a) Any machine modifications are strictly prohibited, and will invalidate
EC certification.
(b) A unique specification for USA/Canada is adopted and tailored to
the territory.
All components, accessories, pipes and connectors added to the
compressed air system should be:
. of good quality, procured from a reputable manufacturer and,
wherever possible, be of a type approved by Ingersoll−Rand.
. clearly rated for a pressure at least equal to the machine maximum
allowable working pressure.
. compatible with the compressor lubricant/coolant.
. accompanied with instructions for safe installation, operation and
maintenance.
FOREWORD 2
TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity
checks.
Use of the machine outside the ambient temperature range
specified in the GENERAL INFORMATION SECTION of this manual.
This machine is not intended and must not be used in potentially
explosive atmospheres, including situations where flammable gases
or vapours may be present.
Use of the machine fitted with non Ingersoll−Rand approved
components / lubricants / fluids.
Use of the machine with safety or control components missing or
disabled.
Use of the machine for storage or transportation of materials inside
or on the enclosure except when contained within the toolbox.
GENERATOR
Use of the generator to supply load(s) greater than those specified.
Use of unsafe or unserviceable electrical equipment connected to
the generator.
Use of electrical equipment:
(a) Having incorrect voltage and/or frequency ratings.
(b) Containing computer equipment and/or similar electronics.
The company accepts no responsibility for errors in translation of
this manual from the original English version.

Details of approved equipment are available from Ingersoll−Rand

Service departments.  COPYRIGHT 2008
DOOSAN COMPANY

The use of repair parts / lubricants / fluids other than those included
within the Ingersoll−Rand approved parts list may create hazardous
conditions over which Ingersoll−Rand has no control. Therefore
Ingersoll−Rand cannot be held responsible for equipment in which
non−approved repair parts are installed.

Ingersoll−Rand reserves the right to make changes and

improvements to products without notice and without incurring any
obligation to make such changes or add such improvements to
products sold previously.

The intended uses of this machine are outlined below and examples
of unapproved usage are also given, however Ingersoll−Rand cannot
anticipate every application or work situation that may arise.

IF IN DOUBT CONSULT SUPERVISION.

This machine has been designed and supplied for use only in the
following specified conditions and applications:
. Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
GENERAL INFORMATION section of this manual.

. Generation of electricity at 110v (1ph) with centre tap earth, 230v

(1ph), 230v (3ph) and 400v (3ph) / 230v (1ph) nominal at 50 Hertz.
(WDG)
The use of the machine in any of the situation types listed in
table 1:−
a) Is not approved by Ingersoll−Rand,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against Ingersoll−Rand.

7/51, 7/71, 12/56

3 WARRANTY
Ingersoll−Rand, through its distributor, warrants that each item of
equipment manufactured by it and delivered hereunder to the initial
user will be free of defects in material and workmanship for a period of
three (3) months from initial operation or six (6) months from the date
of shipment to the initial user, whichever occurs first.
With respect to the following types of equipment, the warranty period
enumerated below will apply in lieu of the foregoing warranty period.
A. Aftercoolers − The earlier of nine (9) months from date of
shipment to or six (6) months from start up by initial user.
B. Portable Compressors, Portable Generator Sets −
9 Kva through to 550 Kva, Portable Light Towers and Air
Dryers − The earlier of twelve (12) months from shipment to or
the accumulation of 2,000 hours of service by the initial user.
2.5 Kva Through to 8 Kva − The earlier of twelve (12) months
from shipment to or the accumulation of 2,000 hours of operation
by the initial user.
Ingersoll−Rand will provide a new part or repaired part, at it’s sole
discretion, in place of any part which is found to be defective in
material or workmanship during the period described above.
Labor cost to replace the part is the responsibility of the initial
user.
C. Portable Compressor Air Ends − The earlier of twenty−four
(24) months from shipment to or the accumulation of 4,000 hours
of service by the initial user. For Air Ends, the warranty against
defects will include replacement of the complete Air End,
provided the original Air End is returned assembled and all
original seals are intact.
C1. Portable Compressor Airend Limited Extended Warranty −
The earlier of sixty (60) months from shipment to or the
accumulation of 10,000 hours of operation by the initial user. This
extended warranty is limited to defects in design or defective
material or workmanship in rotors, housings, bearings and gears
and provided all the following conditions are met:
The original air end is returned assembled and all original seals
are intact.
Continued use of genuine Ingersoll−Rand parts, fluids, oils and
filters.
Maintenance is performed at prescribed intervals by authorized
and properly trained service engineers.
D. Generator Alternator − 9 Kva through to 550 Kva. The earlier
of twenty−four (24) months from shipment to or the accumulation
of 4,000 hours of operation by the initial user.
2.5 Kva Through to 8 Kva − The earlier of twelve (12) months
from shipment to or the accumulation of 2,000 hours of operation
by the initial user.
E. Portable Light Tower Alternator − The earlier of twelve (12)
months from shipment to or the accumulation of 2,000 hours of
operation by the initial user. Light Source model only, the earlier
of twenty−four (24) months from shipment to or the accumulation
of 4,000 hours of operation by the initial user.
F. Ingersoll−Rand Engines − The earlier of twenty−four (24)
months from shipment to or the accumulation of 4,000 hours of
operation by the initial user.
7/51, 7/71, 12/56
G. Ingersoll−Rand Platinum Drive Train Limited Extended
Warranty − Platinum drive train refers to the Ingersoll−Rand
Engine and Airend combination. The earlier of sixty (60) months
from shipment to, or the accumulation of 10,000 hours of
operation by the initial user. The starter, alternator, fuel injection
system and all electrical components are excluded from this
extended warranty. The airend seal and drive coupling are
included in the warranty but airend drive belts are excluded. This
limited extended warranty is automatically available when
meeting the following conditions are met:
1. The original airend is returned assembled and unopened.
2. Continued use of genuine Ingersoll−Rand parts, fluids, oil and
filters.
3. Maintenance is performed at prescribed intervals by
authorized and properly trained service engineers.
Ingersoll−Rand shall be provided with such information as it
requires to confirm that these conditions have been complied
with.
H1. Construction Tools, (Portable Power range only) − Twelve
(12) months from shipment to initial user. Ingersoll−Rand will
provide a new part or repaired part, at it’s sole discretion, in place
of any part which is found to be defective in material or
workmanship during the period described above. Labor cost to
replace the part is the responsibility of the initial user.
H2. Construction Tools Limited Extended Warranty, (Portable
Power range only) − Thirty−six (36) months from shipment to
initial user. This extended warranty is automatically available
only when the tool is registered with Ingersoll−Rand by
completing and submitting the Warranty Registration form.
Ingersoll−Rand will provide a new part or repaired part, at it’s sole
discretion, in place of any part which is found to be defective in
material or workmanship during the period described above.
Labor cost to replace the part is the responsibility of the initial
user.
I. Spare Parts − Six (6) months from date of shipment to the initial
user.
Ingersoll−Rand will provide a new part or repaired part, at its sole
discretion, in place of any part that is found to be defective in material
and workmanship during the period described above. Such parts will
be repaired or replaced without charge to the initial user during normal
working hours at the place of business of an Ingersoll−Rand distributor
authorized to sell the type of equipment involved or other establishment
authorized by Ingersoll−Rand. User must present proof of purchase at
the time of exercising warranty.
The above warranties do not apply to failures occurring as a result of
abuse; misuse, negligent repairs, corrosion, erosion and normal wear
and tear, alterations or modifications made to the product without
express written consent of Ingersoll−Rand; or failure to follow the
recommended operating practices and maintenance procedures as
provided in the product’s operating and maintenance publications.
Accessories or equipment furnished by Ingersoll−Rand, but
manufactured by others, including, but not limited to, engines, tires,
batteries, engine electrical equipment, hydraulic transmissions,
carriers, shall carry only the manufacturers warranty, which
Ingersoll−Rand can lawfully assign to the initial user.
THE ABOVE WARRANTIES ARE IN LIEU OF ALL OTHER
WARRANTIES EXPRESSED OR IMPLIED, (EXCEPT THAT OF
TITLE), AND THERE ARE NO WARRANTIES OF
MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.
 WARRANTY 4
GENERAL WARRANTY INFORMATION − ESA

COMMENTS

PORTABLE COMPRESSOR PACKAGE 12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,
HOURS RADIATOR, OIL COOLER, RECEIVER, PIPEWORK,
ELECTRICAL CIRCUIT ETC.

AIREND 24 MONTHS / 4,000 60 MONTHS / 10,000 HOURS. EXTENDED LIMITED

HOURS WARRANTY AVAILABLE ON MAJOR COMPONENTS.
REFER TO OPERATOR’S MANUAL.

ENGINE SEE BELOW

2.5kVA − 8kVA PACKAGE 12 MONTHS / 2,000 CONTACT IR NETWORK FOR WARRANTY (PARTS
GENERATORS HOURS ONLY NO LABOUR).

ALTERNATOR 12 MONTHS / 2,000 CONTACT IR NETWORK FOR WARRANTY (PARTS

HOURS ONLY NO LABOUR).

ENGINE SEE BELOW

9kVA − 550kVA PACKAGE 12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,
GENERATORS HOURS ELECTRICAL CIRCUIT ETC.

ALTERNATOR 24 MONTHS / 4,000 CONTACT IR NETWORK FOR WARRANTY.

HOURS

ENGINE SEE BELOW

LIGHT TOWER PACKAGE 12 MONTHS / 2,000 COVERS CONTROLS, SWITCHES, SHEET METAL,
HOURS ELECTRICAL CIRCUIT ETC.

ALTERNATOR 12 MONTHS / 2,000 EXTENDED WARRANTY OF 24 MONTHS / 4,000 HRS.

HOURS FOR LIGHTSOURCE INTRODUCED 8/16/99.

ENGINE SEE BELOW

ENGINES

MONTHS HOURS COMMENTS

CATERPILLAR 12 UNLIMITED EXTENDED WARRANTY PROVIDED VIA ENGINE

SUPPLIER’S OWN APPROVED NETWORK AT TIME OF
PURCHASE.

CUMMINS 24 2,000 EXTENDED WARRANTY PROVIDED VIA ENGINE

SUPPLIER’S OWN APPROVED NETWORK AT TIME OF
PURCHASE.

PERKINS 12 UNLIMITED IF UNDER 500 HOURS IN FIRST YEAR THEN BELOW

APPLIES.

24 1,000 ALL COMPONENTS COVERED EXCLUDING

INJECTORS.

JOHN DEERE 24 2,000 5 YRS/5,000 HRS USING OEM FLUIDS AND FILTERS
(IN COMPRESSORS) WITH $250 DEDUCTABLE

(IN GENERATORS) 24 2,000 24 MONTHS / 4,000 HRS. AVAILABLE FROM IR WITH

USE OF GENUINE IR PARTS AND OILS AT
PRESCRIBED SERVICE INTERVALS. CONTACT IR
NETWORK.

DEUTZ 0 − 12 UNLIMITED ALL COMPONENTS COVERED.

13 − 24 UNLIMITED MAJOR COMPONENTS COVERED. FURTHER

EXTENDED WARRANTY ON MAJOR COMPONENTS
PROVIDED VIA ENGINE SUPPLIER’S OWN APPROVED
NETWORK AT TIME OF PURCHASE.

INGERSOLL−RAND 24 4,000 EXTENDED WARRANTY OF 60 MONTHS / 10,000 HRS.

WHEN USING GENUINE INGERSOLL−RAND FLUIDS
AND PARTS ON MAJOR COMPONENTS.
7/51, 7/71, 12/56
5 WARRANTY
KUBOTA 24 2,000 EXTENDED WARRANTY OF 36 MONTHS / 3,000 HRS.
(North America only) ON MAJOR COMPONENTS, PARTS ONLY, AVAILABLE
FROM KUBOTA.

(Western Europe and Oceania) 24 2,000 NO EXTENDED WARRANTY AVAILABLE.

(Central and South America, Asia, 12 1,000 NO EXTENDED WARRANTY AVAILABLE.

Middle East and Africa)

MITSUBISHI 24 2,000 2YRS / 4,000 HRS USING IR FLUIDS AND FILTERS

VOLVO 24 2,000 2YRS / 4,000 HRS USING IR FLUIDS AND FILTERS

PARTS

MONTHS HOURS COMMENTS

INGERSOLL−RAND 6 UNLIMITED PARTS ONLY AVAILABLE FROM IR NETWORK.

AIREND EXCHANGE

MONTHS HOURS COMMENTS

AIREND 12 2,000 24 MONTHS / 4,000 HRS. AVAILABLE FROM IR

NETWORK.

CONSTRUCTION TOOLS

MONTHS HOURS COMMENTS

CONSTRUCTION TOOLS 12 N/A OPTIONAL 36 MONTHS EXTENDED WARRANTY

AVAILABLE FROM IR. ALL WARRANTY COVERS PARTS
ONLY REPLACEMENT.

NOTE: Actual warranty times may change.

Consult the Manufacturer’s warranty policy as shipped with each
new product.

7/51, 7/71, 12/56

 WARRANTY 6
Extended Limited Airend Warranty
Ingersoll−Rand Portable Compressor Division is pleased to announce the availability of extended limited airend warranty. Announcement of the
extended warranty coincides with the introduction of Pro−Tec
Compressor Fluid. Pro−Tec
Compressor Fluid is an amber coloured fluid specially
formulated for Portable Compressors and is being provided as the factory filled fluid for all machines except 1 XHP650/900/1070

All machines have the standard airend warranty, − The earlier of 24 months from shipment to, or the accumulation of 4000 hours of service by the
initial user.

The warranty against defects will include replacement of the complete Airend, provided the original Airend is returned assembled and unopened.

The optional limited warranty is the earlier of 60 months from shipment to, or the accumulation of 10,000 hours of service. The optional warranty
is limited to defects in major components (rotors, housings, gears and bearings), and is automatically available when the following conditions are met:

1. The original airend is returned assembled and unopened.

2. Submissions of proof that Ingersoll−Rand fluid, filters and separators have been used. Refer to the Operation and Parts manual for the correct fluids,
filters and separator elements required.

3. Submissions of proof that maintenance intervals have been followed.

WARRANTY TIME *BARE AIREND **AIREND COMPONENTS

STANDARD 2YRS / 4,000HRS 100% PARTS & LABOUR 100% PARTS & LABOUR
OPTIONAL 5YRS / 10,000HRS 100% PARTS & LABOUR 0%

*BARE AIREND − pertains to major airend parts (rotors, housings, gears and bearings).

**AIREND COMPONENTS − pertains to auxiliary attachments to the bare airend (seals, pumps, valves, tubes, hoses, fittings and filter housing).

Pro−Tec
and XHP505 Compressor Fluids are available from your local Ingersoll−Rand branch or distributor.

For units operating within the USA & Canada, call the Mocksville Product Support Department on 1−800−633−5206

1 XHP650/900/1070/1170 will continue to use XHP505 and will have the extended warranty when above conditions are met.

7/51, 7/71, 12/56

7 WARRANTY

WARRANTY REGISTRATION
FOR UNITS SOURCED FROM DUBLIN, IRELAND
Complete Machine Registration

To initiate the machine warranty, fill out the ”Warranty Registration” form 85040285 supplied as part of the machine documentation, keep a copy for
your records and mail the original to:

Doosan Warranty Team

Doosan Trading Limited
170/175 Lakeview Drive
Airside Business Park
Swords, Co. Dublin
Ireland

Fax: (+353) 1 870 7404

Email: doosanwarranty@dii.doosan.com

Note: Completion of this form validates the warranty.

Engine Registration:
I−R powered machines do not require separate engine registration.

Deutz require a separate engine registration form to be completed and mailed direct to their Cologne office. The form is supplied as part of the machine
documentation for Deutz powered machines.

Caterpillar, Cummins and Perkins do not require a separate registration form but they stipulate that any new engine should be registered with their local
dealer to initiate warranty.

You MUST provide proof of the “in−service” date when requesting engine warranty repairs.

7/51, 7/71, 12/56

 WARRANTY 8

PORTABLE POWER
EXTENDED WARRANTY REGISTRATION FORM

Customer Details Service Provider Details

Company Name : Service Provider / Distributor :

Contact Name : Branch Office :

Signature :

Company Address : Machine Details

Product Type :

Model :

Serial Number :

SAMPLE
Engine Serial Number :

Engine Model Number :

Post / Zip Code : Airend Serial Number :

Country : Alternator Serial Number :

Phone Number : Date of start up :

Fax Number :

e−mail :

7/51, 7/71, 12/56

9 DECALS

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING − Pressurised component or WARNING − Hot surface.
system.

WARNING − Pressure control. WARNING − Corrosion risk. WARNING − Air/gas flow or Air discharge.

X,X BAR

WARNING − Maintain correct tyre pressure.

WARNING − Pressurised vessel. WARNING − Hot and harmful exhaust gas. (Refer to the GENERAL INFORMATION
section of this manual).

0C

WARNING − Before connecting the tow bar WARNING − For operating temperature
WARNING − Flammable liquid. or commencing to tow consult the below 0C, consult the operation and
operation and maintenance manual. maintenance manual.

7/51, 7/71, 12/56

 DECALS 10

WARNING − Do not undertake any

WARNING − Consult the operation and
maintenance on this machine until the Do not breathe the compressed air from this
maintenance manual before commencing
electrical supply is disconnected and the air machine.
any maintenance.
pressure is totally relieved.

Do not remove the Operating and Maintenance Do not operate the machine without the guard
Do not stack.
manual and manual holder from this machine. being fitted.

Do not stand on any service valve or other Do not operate with the doors or enclosure
Do not use fork lift truck from this side.
parts of the pressure system. open.

XX
km/h
Do not open the service valve before the
Do not exceed the trailer speed limit. No naked lights.
airhose is attached.

Use fork lift truck from this side only. Emergency stop. Tie down point

7/51, 7/71, 12/56

11 DECALS

Lifting point. On (power). Off (power).

Read the Operation and Maintenance manual

When parking use prop stand, handbrake and
before operation or maintenance of this Compressor oil filling
wheel chocks.
machine is undertaken.

Diesel fuel Rough Service Designation.

Parking brake.
No open flame. Wet Location Operation.

Replace any cracked protective shield. Oil drain.

7/51, 7/71, 12/56

 DECALS 12
Look for these signs on machines shipped to markets in North America, which point out potential hazards
to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions.
If you do not understand, inform your supervisor.

DANGER CAUTION
Red background Yellow background
Indicates the presence of a hazard which WILL cause Indicates the presence of a hazard which WILL or can
serious injury, death or property damage, if ignored. cause injury or property damage, if ignored.

WARNING NOTICE
Orange background Blue background
Indicates the presence of a hazard which CAN cause Indicates important set−up, operating or maintenance
serious injury, death or property damage, if ignored. information.

DANGER WARNING
Trapped air pressure. Can
cause serious injury or
death.

Close service valve and

operate tool to vent trapped air
before performing any service.
Air discharged from this machine can contain
carbon monoxide or other contaminants which
will cause serious injury or death.
Do not breathe this air.

WARNING WARNING
Hot pressurized fluid. Rotating Fan Blade.
Can cause serious burns. CAN cause serious injury.

Do not open radiator while Do NOT operate with guard

hot. removed.

7/51, 7/71, 12/56

13 DECALS

WARNING WARNING
Improper operation of this equipment. Trapped air pressure.
CAN cause serious injury or death. Can cause serious injury
or death.
Read Operator’s Manual supplied with this machine
before operation or servicing. Close service valve and
operate tool to vent trapped
Modification or alteration of this machine.
air before performing any
CAN cause serious injury or death.
service.
Do NOT alter or modify this machine without the
express written consent of the manufacturer.

WARNING

WARNING
Disconnected Air Hoses
Whip. CAN cause
serious injury or death.
When using air tools attach
safety device
(OSHA Valve) at source of
air supply for each tool. Falling off machine. CAN cause serious
injury or death.

Access Lifting Bail from inside machine.

WARNING

WARNING
High pressure air. Can
cause serious injury or
death.

Relieve pressure before

removing filler plugs/ Door under pressure CAN cause serious
caps, fittings or covers. injury.

Use both hands to open door when machine

is running.

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 DECALS 14

WARNING

WARNING
Collapsing propstand.
Can cause serious injury.
Excessive Towing Speed. CAN cause
Clamp propstand securely serious injury or death.
Do NOT Tow on Highway.
Excessive towing speed. Do NOT exceed 20 mph (32 km/h)
Can cause serious injury or
death.
Do NOT exceed 65 mph (105
km/hr)

For Highway Towable Units. For Non−Highway Towable Machines

FREE SAFETY DECALS!

Safety Decals are available free of charge. Safety decals
are identified by the decal heading:
DANGER, WARNING or CAUTION.

Decal part numbers are on the bottom of each decal and

are also listed in the compressor’s parts manual. Submit
orders for Safety Decals to the Doosan Portable Power
EMEA Aftermarket Department. The no charge order
should contain only Safety Decals. Help promote product
safety! Assure that decals are present on the machines.
Replace decals that are not readable.

7/51, 7/71, 12/56

15 NOISE EMISSION

This section pertains only to machines distributed within the

United States.
WARNING
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof:

(1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of
design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;
or (2) the use of the compressor after such device or element of design has been removed or rendered inoperative by any person.

Among those acts included in the prohibition against tampering are these:

1. Removal or rendering inoperative any of the following:

a. the engine exhaust system or parts thereof
b. the air intake system or parts thereof
c. enclosure or parts thereof

2. Removal of any of the following:

a. fan shroud
b. vibration mounts
c. sound absorption material

3. Operation of the compressor with any of the enclosure doors open.

Compressor Noise Emission Control Information

A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or replacement of any noise control device or element of
design incorporated into this compressor in compliance with the noise control act;

B. The use of this compressor after such device or element of design has been removed or rendered inoperative.

Note: the above information applies only to units that are built in compliance with the U.S. Environmental Protection Agency.

Ingersoll−Rand Company reserves the right to make changes or add improvements without notice and without incurring any obligation to make such
changes or add such improvements to products sold previously.

The Purchaser is urged to include the above provisions in any agreement for any resale of this compressor.

7/51, 7/71, 12/56

 NOISE EMISSION 16

NOISE EMISSION CONTROL

MAINTENANCE LOG

COMPRESSOR MODEL

SERIAL NO.

USER UNIT NO.

UNIT IDENTIFICATION DEALER OR DISTRIBUTOR

ENGINE MAKE & MODEL: FROM WHOM PURCHASED:
SERIAL NO.:
PURCHASER OR OWNER:
ADDRESS:
DATE PURCHASED:

The Noise Control Act of 1972 (86 Stat. 1234) prohibits tampering with the noise control system of any compressor manufactured and sold under
the above regulations, specifically the following acts or the causing thereof:

(1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of
design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use;
or (2) the use of the compressor after such a device or element of design has been removed or rendered inoperative by any person.

NOISE EMISSION WARRANTY

The manufacturer warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, built and equipped
to conform at the time of sale to the first retail purchaser, with all applicable U.S. EPA Noise Control Regulations.

This warranty is not limited to any particular part, component, or system of the air compressor. Defects in the design, assembly, or in any part,
component, or system of the compressor which, at the time of sale to the first retail purchaser, caused noise emissions to exceed Federal Standards
are covered by this warranty for the life of the air compressor. (40FR204.58−1).

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17 NOISE EMISSION
INTRODUCTION
The unit for which this Maintenance Log is provided conforms to U.S. E.P.A. Regulations for Noise Emissions, applicable to Portable Air
Compressors.

The purpose of this book is to provide (1) the Maintenance Performance Schedule below for all required noise emission controls and (2) space
so that the purchaser or owner can record what maintenance was done, by whom, where and when. Detailed instructions on the maintenance items
below are given on the following page.

MAINTENANCE SCHEDULE

ITEM AREA PERIOD

A. COMPRESSED AIR LEAKS AS DETECTED
B. SAFETY AND CONTROL SYSTEMS AS DETECTED
C. ACOUSTIC MATERIALS DAILY
D. FASTENERS 100 HOURS
E. ENCLOSURE PANELS 100 HOURS
F. AIR INTAKE & ENGINE EXHAUST 100 HOURS
G. COOLING SYSTEMS 250 HOURS
H. ISOLATION MOUNTS 250 HOURS
I. ENGINE OPERATION SEE OPERATOR’S MANUAL
J. FUELS & LUBRICANTS SEE OPERATOR’S MANUAL

7/51, 7/71, 12/56


A. COMPRESSED AIR LEAKS
Correct all compressed air leaks during the first shutdown period
after discovery. If severe enough to cause serious noise problems and
efficiency loss, shut down immediately and correct the leak(s).
B. SAFETY AND CONTROL SYSTEMS
Repair or replace all safety and control systems or circuits as
malfunction occurs. No compressor should be operated with either
system bypassed, disabled, or nonfunctional.
C. ACOUSTIC MATERIALS
In daily inspections, observe these materials. Maintain all
acoustic material as nearly as possible in its original condition. Repair
or replace all sections that have: 1) sustained damage, 2) have partially
separated from panels to which they were attached, 3) are missing, or
have otherwise deteriorated due to severe operating or storage
conditions.
D. FASTENERS
All fasteners such as hinges, nuts, bolts, clamps, screws, rivets
and latches should be inspected for looseness after each 100 hours of
operation. They should be retightened, repaired, or − if missing −
replaced immediately to prevent subsequent damage and noise
emission increase.
E. ENCLOSURE PANELS
Enclosure panels should also be inspected at 100 hour
operational intervals. All panels that are warped, punctured, torn, or
otherwise deformed, such that their noise containment function is
reduced, should be repaired or replaced before the next operation
interval. Doors, access panels, and hatch closures especially, should
be checked and adjusted at this time to insure continuous sealing
between gasket or acoustic material and the mating frame.
NOISE EMISSION 18
F. AIR INTAKE AND ENGINE EXHAUST
Engine and compressor air intake and engine exhaust systems
should be inspected after each 100 hours of operation for loose,
damaged, or deteriorated components. Repairs or replacements
should be made before the next period of use.
G. COOLING SYSTEMS
All components of the cooling systems for engine water and
compressor oil should be inspected every 250 hours of use. Any
discrepancies found should be corrected before placing the unit back
in operation. Unrestricted airflow over the radiator and oil cooler must
be maintained at all times during operation.
H. ISOLATION MOUNTS
Engine/airend isolation mounts should be inspected after each
250 hours of operation. Those mounts with cracks or splits in the
molded rubber, or with bent or broken bolts due to operation or storage
in severe environments, all should be replaced with equivalent parts.
I. ENGINE OPERATION
Inspect and maintain engine condition and operation as
recommended in the manuals supplied by the engine manufacturer.
J. FUELS AND LUBRICANTS
Use only the types and grades of fuels and lubricants
recommended in the Ingersoll−Rand Company and Engine
Manufacturer’s Operator and Maintenance Manuals.
7/51, 7/71, 12/56
19 MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY

MAINTENANCE RECORD FOR NOISE EMISSION CONTROL AND EXTENDED WARRANTY

ITEM NO. DESCRIPTION OF WORK OR HOURMETER MAINT/INSPECT LOCATION WORK DONE BY

COMMENTS READING DATE CITY/STATE (NAME)

7/51, 7/71, 12/56


WARNINGS
Warnings call attention to instructions which must be followed
precisely to avoid injury or death.
CAUTIONS
Cautions call attention to instructions which must be followed
precisely to avoid damaging the product, process or its surroundings.
NOTES
Notes are used for supplementary information.
General Information
Never operate unit without first observing all safety warnings and
carefully reading the operation and maintenance manual shipped from
the factory with this machine.
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation.
Ensure that the Operation and Maintenance manual, and the
manual holder, are not removed permanently from the machine.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
Make sure that all protective covers are in place and that the
canopy/doors are closed during operation.
The specification of this machine is such that the machine is not
suitable for use in flammable gas risk areas. If such an application is
required then all local regulations, codes of practice and site rules must
be observed. To ensure that the machine can operate in a safe and
reliable manner, additional equipment such as gas detection, exhaust
spark arrestors, and intake (shut−off) valves may be required,
dependant on local regulations or the degree of risk involved.
A weekly visual check must be made on all fasteners/fixing screws
securing mechanical parts. In particular, safety−related parts such as
coupling hitch, drawbar components, road−wheels, and lifting bail
should be checked for total security.
All components which are loose, damaged or unserviceable, must
be rectified without delay.
Air discharged from this machine may contain carbon monoxide or
other contaminants which will cause serious injury or death. Do not
breathe this air.
This machine produces loud noise with the doors open or service
valve vented. Extended exposure to loud noise can cause hearing loss.
Always wear hearing protection when doors are open or service valve
is vented.
Never inspect or service unit without first disconnecting battery
cable(s) to prevent accidental starting.
Do not use petroleum products (solvents or fuels) under high
pressure as this can penetrate the skin and result in serious illness.
wear eye protection while cleaning unit with compressed air to prevent
debris from injuring eye(s).
Rotating fan blade can cause serious injury. Do not operate without
guard in place.
Use care to avoid contacting hot surfaces (engine exhaust manifold
and piping, air receiver and air discharge piping, etc.).
SAFETY 20
Ether is an extremely volatile, highly inflammable gas. When it is
specified as a starting aid, use sparingly. DO NOT USE ETHER IF THE
MACHINE HAS GLOW PLUG STARTING AID OR ENGINE DAMAGE
WILL RESULT.
Never operate unit with guards, covers or screens removed. Keep
hands, hair, clothing, tools, blow gun tips, etc. well away from moving
parts.
Compressed air
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
Ensure that the machine is operating at the rated pressure and that
the rated pressure is known to all relevant personnel.
All air pressure equipment installed in or connected to the machine
must have safe working pressure ratings of at least the machine rated
pressure.
If more than one compressor is connected to one common
downstream plant, effective check valves and isolation valves must be
fitted and controlled by work procedures, so that one machine cannot
accidentally be pressurised / over pressurised by another.
Compressed air must not be used for a direct feed to any form of
breathing apparatus or mask.
High Pressure Air can cause serious injury or death. Relieve
pressure before removing filler plugs/caps, fittings or covers.
Air pressure can remain trapped in air supply line which can result
in serious injury or death. Always carefully vent air supply line at tool
or vent valve before performing any service.
The discharged air contains a very small percentage of compressor
lubricating oil and care should be taken to ensure that downstream
equipment is compatible.
If the discharged air is to be ultimately released into a confined
space, adequate ventilation must be provided.
When using compressed air always use appropriate personal
protective equipment.
All pressure containing parts, especially flexible hoses and their
couplings, must be regularly inspected, be free from defects and be
replaced according to the Manual instructions.
Avoid bodily contact with compressed air.
The safety valve located in the separator tank must be checked
periodically for correct operation.
Whenever the machine is stopped, air will flow back into the
compressor system from devices or systems downstream of the
machine unless the service valve is closed. Install a check valve at the
machine service valve to prevent reverse flow in the event of an
unexpected shutdown when the service valve is open.
7/51, 7/71, 12/56
21 SAFETY
Disconnected air hoses whip and can cause serious injury or death.
Always attach a safety flow restrictor to each hose at the source of
supply or branch line in accordance with OSHA Regulation 29CFR
Section 1926.302(b).
Never allow the unit to sit stopped with pressure in the
receiver−separator system.
Materials
The following substances may be produced during the operation of
this machine:
. brake lining dust
. engine exhaust fumes
AVOID INHALATION
Ensure that adequate ventilation of the cooling system and exhaust
gases is maintained at all times.
The following substances are used in the manufacture of this
machine and may be hazardous to health if used incorrectly:
. compressor lubricant
. engine lubricant
. preservative grease
. rust preventative
. diesel fuel
. battery electrolyte
AVOID INGESTION, SKIN CONTACT AND INHALATION OF
FUMES.
Should compressor lubricant come into contact with the eyes, then
irrigate with water for at least 5 minutes.
Should compressor lubricant come into contact with the skin, then
wash off immediately.
Consult a physician if large amounts of compressor lubricant are
ingested.
Consult a physician if compressor lubricant is inhaled.
Never give fluids or induce vomiting if the patient is unconscious or
having convulsions.
Safety data sheets for compressor and engine lubricants should be
obtained from the lubricant supplier.
Never operate the engine of this machine inside a building without
adequate ventilation. Avoid breathing exhaust fumes when working on
or near the machine.
This machine may include such materials as oil, diesel fuel,
antifreeze, brake fluid, oil/air filters and batteries which may require
proper disposal when performing maintenance and service tasks.
Contact local authorities for proper disposal of these materials.
Battery
A battery contains sulphuric acid and can give off gases which are
corrosive and potentially explosive. Avoid contact with skin, eyes and
clothing. In case of contact, flush area immediately with water.
7/51, 7/71, 12/56
DO NOT ATTEMPT TO SLAVE START A FROZEN BATTERY
SINCE THIS MAY CAUSE IT TO EXPLODE.
Exercise extreme caution when using booster battery. To jump
battery, connect ends of one booster cable to the positive (+) terminal
of each battery. Connect one end of other cable to the negative (−)
terminal of the booster battery and other end to a ground connection
away from dead battery (to avoid a spark occurring near any explosive
gases that may be present). After starting unit, always disconnect
cables in reverse order.
Radiator
Hot engine coolant and steam can cause injury. Ensure that the
radiator filler cap is removed with due care and attention.
Do not remove the pressure cap from a HOT radiator. Allow radiator
to cool down before removing pressure cap.
Generator sets
The generator set is designed for safety in use. However, the
responsibility for safe operation rests with those who install, use and
maintain it. The following safety precautions are offered as a guide,
which, if conscientiously followed, will minimise the possibility of
accidents throughout the useful life of this equipment.
Emergency Stop Controls
Important Note:− In addition to the key operated emergency stop
control on the main control panel, a second control is provided at the
socket control panel in the event of electrical hazards associated with
generator operation. Use this second control to immediately isolate all
electrical power to all sockets, then use the key control to stop the
engine.
Operation of the generator must be in accordance with recognised
electrical codes and local health and safety codes.
The generator set should be operated by those who have been
trained in its use and delegated to do so, and who have read and
understand the operator’s manual. Failure to follow the instructions,
procedures and safety precautions in the manual may increase the
possibility of accidents and injuries.
Do not start the generator set unless it is safe to do so. Do not
attempt to operate the generator set with a known unsafe condition. Fit
a danger notice to the generator set and render it inoperative by
disconnecting the battery and disconnecting all ungrounded
conductors so others who may not know of the unsafe condition will not
attempt to operate it until the condition is corrected.
An earth point is provided beneath the socket outlets.
The generator set should only be used with the earth point
connected directly to the general earth/ground mass. An earth spike kit
is available as an optional extra for this purpose (refer to the parts
catalogue).
WARNING: DO NOT OPERATE THE MACHINE UNLESS IT HAS
BEEN SUITABLY EARTHED.
Generator sets must be connected to the load only by trained and
qualified electricians who have been delegated to do so, and when
required by applicable regulations, their work should be inspected, and
accepted by the inspection agency having authority, prior to attempting
to operate the generator set.
Do not make contact with electrically energised parts of the
generator set and/or interconnecting cables or conductors with any
part of the body or with any non−insulated conductive object.

Make sure the generator set is effectively grounded in accordance
with all applicable Regulations prior to attempting to make or break load
connections and prior to attempting operation.
Do not attempt to make or break electrical connections to generator
sets standing in water or on wet ground.
Prior to attempting to make or break electrical connections at the
generator set, stop the engine, disconnect the battery and disconnect
and lock out the ungrounded conductors at the load end.
Keep all parts of the body and any hand−held tools or other
conductive objects, away from exposed live parts of the generator set
engine electrical system. Maintain dry footing, stand on insulating
surfaces and do not contact any other portion of the generator set when
making adjustments or repairs to exposed live parts of the generator
set engine electrical system.
Replace the generator set terminal compartment cover as soon as
connections have been made or broken. Do not operate the generator
set without the terminal cover secured firmly in place.
Close and lock all access doors when the generator set is left
unattended.
Do not use extinguishers intended for Class A or Class B fires on
electrical fires. Use only extinguishers suitable for class BC or class
ABC fires.
Keep the towing vehicle or equipment carrier, generator set,
connecting cables, tools and all personnel at least 3 metres from all
power lines and buried power cables, other than those connected to the
generator set.
Attempt repairs only in clean, dry, well lighted and ventilated areas.
Connect the generator set only to loads and/or electrical systems
that are compatible with its electrical characteristics and that are within
it’s rated capacity.
Transport
When loading or transporting machines ensure that the specified
lifting and tie down points are used.
When loading or transporting machines ensure that the towing
vehicle, its size, weight, towing hitch and electrical supply are all
suitable to provide safe and stable towing at speeds either, up to the
legal maximum for the country in which it is being towed or, as specified
for the machine model if lower than the legal maximum.
Ensure that the maximum trailer weight does not exceed the
maximum gross weight of the machine (by limiting the equipment load),
limited by the capacity of the running gear.
Note:
Gross mass (on data plate) is for the basic machine and fuel only,
excluding any fitted options, tools, equipment and foreign materials.
Before towing the machine, ensure that:−
. the tyres and towing hitch are in a serviceable condition.
. the canopy is secure.
. all ancillary equipment is stored in a safe and secure manner.
. the brakes and lights are functioning correctly and meet necessary
road traffic requirements.
. break-away cables/safety chains are connected to the towing
vehicle.
SAFETY 22
The machine must be towed in a level attitude in order to maintain
correct handling, braking and lighting functions. This can be achieved
by correct selection and adjustment of the vehicle towing hitch and, on
variable height running gear, adjustment of the drawbar.
To ensure full braking efficiency, the front (towing eye) section must
always be set level.
When adjusting variable height running gear:−
Ensure front (towing eye) section is set level
When raising towing eye, set rear joint first, then front joint.
When lowering towing eye, set front joint first, then rear joint.
After setting, fully tighten each joint by hand and then tighten further to
the next pin. Refit the pin.
When parking always use the handbrake and, if necessary, suitable
wheel chocks.
Make sure wheels, tyres and tow bar connectors are in safe
operating condition and tow bar is properly connected before towing.
Safety chains / connections and their adjustment
The legal requirements for the joint operation of the breakaway
cable and safety chains are as yet unidentified by 71/320/EEC or UK
regulations. Consequently we offer the following advice / instructions.
Where brakes only are fitted:
a) Ensure that the breakaway cable is securely coupled to the
handbrake lever and also to a substantial point on the towing vehicle.
b) Ensure that the effective cable length is as short as possible, whilst
still allowing enough slackness for the trailer to articulate without the
handbrake being applied.
Where brakes and safety chains are fitted:
a) Loop the chains onto the towing vehicle using the towing vehicle
hitch as an anchorage point, or any other point of similar strength.
b) Ensure that the effective chain length is as short as possible whilst
still allowing normal articulation of the trailer and effective operation of
the breakaway cable.
Where safety chains only are fitted:
a) Loop the chains onto the towing vehicle using the towing vehicle
hitch as an anchorage point, or any other point of similar strength.
b) When adjusting the safety chains there should be sufficient free
length in the chains to allow normal articulation, whilst also being short
enough to prevent the towbar from touching the ground in the event of
an accidental separation of the towing vehicle from the trailer.
7/51, 7/71, 12/56
23 GENERAL INFORMATION

7/51 FIXED HEIGHT RUNNING GEAR

Braked version (Knott)

7/51 VARIABLE HEIGHT RUNNING GEAR

Braked version (Knott)

7/51, 7/71, 12/56

 GENERAL INFORMATION 24
7/71, 12/56 FIXED HEIGHT RUNNING GEAR
Braked version

7/71, 12/56 VARIABLE HEIGHT RUNNING GEAR

Braked version

7/51, 7/71, 12/56

25 GENERAL INFORMATION
COMPRESSOR In the event that Pro−TecTM is not available and / or the end user
needs to use an approved single grade engine oil, the complete system
Actual free air delivery. 5,0 m3 min−1 (175 CFM) including separator / receiver, cooler and pipework must be flushed
(7/51) clear of the first fill fluid and new Ingersoll−Rand oil filters installed.
Actual free air delivery. 7,1 m3 min−1 (250 CFM) When this has been completed, the following oils are approved:
(7/71)
Actual free air delivery. 5,6 m3 min−1 (200 CFM) a) for ambient temperatures above −23C (−9F),
(12/56) SAE 10W, API CF−4/CG−4

Normal operating discharge pressure. 7 bar (100 PSI)

b) for ambient temperatures below −23C (−9F),
(7/51, 7/71)
I−R Performance 500 only.
Normal operating discharge pressure. 12 bar (175 PSI)
(12/56)
Safety data sheets can be obtained on request from the lubricant
Maximum allowable pressure. 8,6 bar (125 PSI) supplier.
(7/51, 7/71)
Maximum allowable pressure. 13 bar (190 PSI) For temperatures outside the specified ambient range, consult
(12/56) Ingersoll−Rand.

Safety valve setting. 10 bar (145 PSI)

(7/51, 7/71)
ENGINE
Safety valve setting. 13,5 bar (200 PSI) 7/51
(12/56)
Type/model. Ingersoll−Rand 4IRI8NE−2
Maximum pressure ratio (absolute). 7,5 : 1 Number of cylinders. 4
(7/51, 7/71)
Oil capacity. 9,5litres (2,5 US GAL)
Maximum pressure ratio (absolute). 11,5 : 1
(12/56) Speed at full load. 2400 revs min−1

Operating ambient temperature. Speed at idle. 1600 revs min−1

Whisperised −10C TO +46C (14F TO 115F) Electrical system. 12V negative earth
Standard −10C TO +52C (14F TO 126F)
Power available at 2400 revs min−1 50,2kW (67,3 HP)
Maximum discharge temperature. 120C (248F)
Fuel tank capacity 50 litres (13,2 US GAL)
Cooling system. Oil injection
Oil specification Refer engine section
Oil capacity. 12 litres (3,2 US GAL)
(7/51) Coolant capacity 11 litres (2,9 US GAL)
Oil capacity. 12,5 litres (3,3 US GAL)
(7/71, 12/56) ENGINE
Maximum oil system temperature. 120C (248F) 7/71, 12/56

Maximum oil system pressure. 8,6 bar (125 PSI) Type/model. Ingersoll−Rand 4IRI8TE
(7/51, 7/71) Number of cylinders. 4

Maximum oil system pressure. 13 bar (190 PSI) Oil capacity. 10,5litres (2,8 US GAL)
(12/56) Speed at full load. 2300 revs min−1
Speed at idle. 1700 revs min−1
LUBRICATING OIL SPECIFICATION
(for the specified ambient temperatures). Electrical system. 12V negative earth
Power available at 2400 revs min−1 59,2kW (79,4 HP)
ABOVE −23C(−9_F)
Recommended: Pro−Tec
Fuel tank capacity 118 litres (31,2 US GAL)
Approved: SAE 10W, API CF−4/CG−4
Oil specification Refer engine section
BELOW −23C(−9_F) Coolant capacity 11 litres (2,9 US GAL)
Mandatory: IR Performance 500

Ingersoll−Rand Pro−TecTM compressor fluid is factory−fitted, for

use at all ambient temperatures above −23C (−9F).

NOTE: Warranty may be extended only by continuous use of

Pro−Tec
and Ingersoll−Rand oil filters and separators.

No other oil/fluids are compatible with Pro−TecTM

No other oils/fluids should be mixed with Pro−TecTM because the

resulting mixture could cause damage to the airend.

7/51, 7/71, 12/56

 GENERAL INFORMATION 26
SOUND LEVEL DATA (‘W’ model) VARIABLE HEIGHT RUNNING GEAR
7/51 Braked version (KNOTT)
7/71, 12/56
A) To Pneurop code PN8NTC2.
Equivalent continuous sound pressure level.* Shipping weight. 1430kg (3153 lbs)
. Rated load 84 dB(A) Maximum weight. 1600kg (3520 lbs)
(Operator position :−1m from machine) Maximum horizontal towing force. 1578 kgf (3479 lbs)
Sound power level (84/533/EEC) 98 dB(A) Maximum vertical coupling load
(nose weight). 100 kgf (220 lbs)
B) In compliance with 86/188/EEC.
Average sound pressure level at 10m
to 79/113/EEC.* 70 dB(A) WHEELS AND TYRES (KNOTT)
Number of wheels. 2 x 41/2 J
(*Machine only :− at maximum load in open site conditions)
7/51
Number of wheels. 2 x 51/2 J
SOUND LEVEL DATA (‘W’ model) 7/71, 12/56
7/71, 12/56
Tyre size. 155 R13
A) To Pneurop code PN8NTC2. 7/51
Equivalent continuous sound pressure level.*
Tyre size. 185 R14
. Rated load 83 dB(A) 7/71, 12/56
(Operator position :−1m from machine) Tyre pressure. 2,9 bar (42 PSI)
Sound power level (84/533/EEC) 99 dB(A) 7/51

B) In compliance with 86/188/EEC. Tyre pressure. 4,5 bar (65 PSI)

7/71, 12/56
Average sound pressure level at 10m
to 79/113/EEC.* 71 dB(A)
Further information may be obtained by request through
(*Machine only :− at maximum load in open site conditions) Ingersoll−Rand customer services department.

FIXED HEIGHT RUNNING GEAR

Braked version (KNOTT)
7/51
Shipping weight. 1010kg (2227 lbs)
Maximum weight. 1200kg (2646 lbs)
Maximum horizontal towing force. 1233 kgf (2720 lbs)
Maximum vertical coupling load
(nose weight). 100 kgf (220 lbs)

VARIABLE HEIGHT RUNNING GEAR

Braked version (KNOTT)
7/51
Shipping weight. 1060kg (2337 lbs)
Maximum weight. 1200kg (2646 lbs)
Maximum horizontal towing force. 1233 kgf (2720 lbs)
Maximum vertical coupling load
(nose weight). 100 kgf (220 lbs)

FIXED HEIGHT RUNNING GEAR

Braked version (KNOTT)
7/71, 12/56
Shipping weight. 1387kg (3058 lbs)
Maximum weight. 1600kg (3520 lbs)
Maximum horizontal towing force. 1578 kgf (3479 lbs)
Maximum vertical coupling load
(nose weight). 100 kgf (220 lbs)

7/51, 7/71, 12/56

27 OPERATING INSTRUCTIONS

COMMISSIONING Ensure that the correct fork lift truck slots or marked lifting / tie down
points are used whenever the machine is lifted or transported.
Upon receipt of the unit, and prior to putting it into service, it is
important to adhere strictly to the instructions given below in PRIOR TO
STARTING. When selecting the working position of the machine ensure that
there is sufficient clearance for ventilation and exhaust requirements,
observing any specified minimum dimensions (to walls, floors etc.).
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation.
Adequate clearance needs to be allowed around and above the
machine to permit safe access for specified maintenance tasks.
Ensure that the position of the emergency stop device is known and
recognised by its markings. Ensure that it is functioning correctly and
that the method of operation is known. Ensure that the machine is positioned securely and on a stable
foundation. Any risk of movement should be removed by suitable
means, especially to avoid strain on any rigid discharge piping.

Running gear drawbar − Machines are shipped to some areas with

the drawbar removed. Fitting involves four nuts / bolts to secure the Attach the battery cables to the battery(s) ensuring that they are
drawbar to the axle and two bolts to fit the drawbar to the front of the tightened securely. Attach the negative cable before attaching the
machine with the saddle and spacer block. positive cable.

Support the front of the machine, fit the wheel chocks to stop the
machine moving and attach the drawbar. Refer to the torque value table
in the MAINTENANCE section of this manual for the correct torque
values.
WARNING: All air pressure equipment installed in or connected
to the machine must have safe working pressure ratings of at least
the machine rated pressure, and materials compatible with the
compressor lubricant (refer to the GENERAL INFORMATION
CAUTION: section).
This is a safety critical procedure. Double check the torque settings
after assembly

Fit the propstand and coupling. Remove the supports and set the
WARNING: If more than one compressor is connected to one
machine level.
common downstream plant, effective check valves and isolation
valves must be fitted and controlled by work procedures, so that
one machine cannot accidentally be pressurised / over
pressurised by another.
Before towing the unit, ensure that the tyre pressures are correct
(refer to the GENERAL INFORMATION section of this manual) and
that the handbrake is functioning correctly (refer to the
MAINTENANCE section of this manual). Before towing the unit during
the hours of darkness, ensure that the lights are functioning correctly
(where fitted).
WARNING: If flexible discharge hoses are to carry more than 7 bar
pressure then it is recommended that safety retaining wires are
Ensure that all transport and packing materials are discarded. used on the hoses.

7/51, 7/71, 12/56

 OPERATING INSTRUCTIONS 28

PRIOR TO STARTING
1. Place the unit in a position that is as level as possible. The design
of the unit permits a 15 degree lengthways and sideways limit on out
of level operation. It is the engine, not the compressor, that is the limiting
factor.
5. Drain the fuel filter water separator of water, ensuring that any
released fuel is safely contained.
6. Open the service valve(s) to ensure that all pressure is relieved
from the system. Close the service valve(s).

When the unit has to be operated out of level, it is important to keep

the engine oil level near the high level mark (with the unit level). 7. CAUTION: Do not operate the machine with the canopy/doors in
the open position as this may cause overheating and operators to be
exposed to high noise levels.
CAUTION: Do not overfill either the engine or the compressor with oil.

2. Check the engine lubrication oil in accordance with the operating
instructions in the Engine Operator’s Manual.
3. Check the compressor oil level in the sight glass located on the
separator tank.
4. Check the diesel fuel level. A good rule is to top up at the end of each
working day. This prevents condensation from occurring in the tank.
CAUTION: Use only a No. 2−D diesel fuel oil with a minimum octane
number of 45 and a sulphur content not greater than 0,5%.
8. Check the radiator coolant level (with the unit level).
Check the air restriction indicator(s). Refer to the MAINTENANCE
section of this manual.
When starting or operating the machine in temperatures below or
approaching 0C, ensure that the operation of the regulation system,
the unloader valve, the safety valve, and the engine are not impaired
by ice or snow, and that all inlet and outlet pipes and ducts are clear of
ice and snow.

CAUTION: When refueling:−

. switch off the engine.
. do not smoke.
. extinguish all naked lights.
. do not allow the fuel to come into contact with hot surfaces.
. wear personal protective equipment.

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29 OPERATING INSTRUCTIONS

STARTING THE MACHINE . Open the service valve fully, with no hose connected.

WARNING: Under no circumstances should volatile liquids such . Complete starting sequence above.
as Ether be used for starting this machine.
. Close service valve as soon as engine runs freely.

All normal starting functions are incorporated in the key operated . Do not allow machine to run for long periods with service valve
switch. open.

. Turn the key switch to position 2 and hold for max 15 seconds to . Allow the engine to reach operating temperature. Then press button
allow the air inlet heater to reach working temperature. (A) when fitted (Option on 7/51, standard on 7/71, 12/56).

. Turn the key switch to position 3 (engine start position).

. At this point in the operation of the machine it is safe to apply full load
to the engine.
. Release to position 2 when the engine starts.

. Release to position 1 when the alternator charge light is

extinguished.

At temperatures below 0_C or if there is difficulty starting first time: NOTE: Wear hearing protection at all times when the engine is started
with the service valve open and air is flowing from the valve.

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DUAL PRESSURE WHEN FITTED
Machines which operate in excess of 7 bar can optionally be fitted with
a dual pressure switch (B). This switch selects between 7 bar and the
machine rated pressure, cfm remains nominally constant.
Starting and stopping are unaffected by the selection and during normal
running the selector switch may be safely operated. Precaution must
be taken to ensure that downstream equipment is rated to suit the
available pressure.
The pressure guage indicates which setting has been selected.
STOPPING THE MACHINE
. Close the service valve.
. Allow the machine to run unloaded for a short period of time to
reduce the engine temperature.
. Turn the start switch to the 0 (off) position.
NOTE: As soon as the engine stops, the automatic blowdown valve will
relieve all pressure from the system.
If the automatic blowdown valve fails to operate, then pressure must
be relieved from the system by means of the service valve(s).
CAUTION: Never allow the machine to stand idle with pressure in the
system.
EMERGENCY STOPPING
In the event that the unit has to be stopped in an emergency, TURN
THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO
THE 0 (OFF) POSITION.
RE−STARTING AFTER AN EMERGENCY
If the machine has been switched off because of a machine
malfunction, then identify and correct the fault before attempting to
re−start.
OPERATING INSTRUCTIONS 30
If the machine has been switched off for reasons of safety, then
ensure that the machine can be operated safely before re−starting.
Refer to the PRIOR TO STARTING and STARTING THE UNIT
instructions earlier in this section before re−starting the machine.
MONITORING DURING OPERATION
Should any of the safety shut-down conditions occur, the unit will
stop. These are:
. Low engine oil pressure
. High air discharge temperature
. High engine water temperature
. Alternator drive belt failure.
. Low engine fuel level.
CAUTION: To ensure an adequate flow of oil to the compressor at low
temperature, never allow the discharge pressure to fall below 3,5 bar.
DECOMMISSIONING
When the machine is to be permanently decommissioned or
dismantled, it is important to ensure that all hazard risks are either
eliminated or notified to the recipient of the machine. In particular:−
. Do not destroy batteries or components containing asbestos
without containing the materials safely.
. Do not dispose of any pressure vessel that is not clearly marked
with its relevant data plate information or rendered unusable by drilling,
cutting etc.
. Do not allow lubricants or coolants to be released into land surfaces
or drains.
. Do not dispose of a complete machine without documentation
relating to instructions for its use.
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31 OPERATING INSTRUCTIONS
Small Electronic Control Unit (SECU) 1. High A/E Temp: Indicates shutdown due to high compressor
temperature.
Display Panel
The SECU display panel is arranged as shown below. A description of 2. High Separator Temp: Indicates shutdown due to high
each diagnostic indicator is as follows: temperature at separator tank discharge.

3. Low Battery Voltage: Alarm indicator. Indicates battery or

charging system requires service.

4. High Engine Coolant Temp: Indictes shutdown due to high engine

water temperature.

5. Low Engine Oil Pressure: Indicates shutdown due to low engine

oil pressure.

6. Compressor Sensor Failure: Indicates pressure sensor

malfunction. Compressor will not start.

7. Low Engine Speed: Indicates shutdown due to low engine speed.

8. Low Fuel Level: Indicates shutdown due to low fuel level.

(Optional)

9. Restricted Air Filter: Alarm indicator. Indicates

engine/compressor air inlet filters need service. (Optional).

A. Engine Communication Error: Engine Model was not

recognized. Compressor will start and operate with a 1700−2300 rpm
range.

C. CAN Communication Error: CAN communication failure.

C. Could be also displayed when EmergencyStop Button (optional)

remains pressed beforeStarting. Engine will not start (crank) in that
case.

E. Generator Enable Switch Error: Generator enable switch on the

control panel remains ON before starting. See also section Options −
generator option. Engine will not start (crank) at that case.

Normal Conditions:
−. Center Bar Blinking: Compressor is ready to start (no faults).

H. Crank Signal Detected: Displayed while start switch is in the

pre−heat or crank position.

During SECU/power up, the 8 digit lights to check the display. Next the
display will step through the 3 digit software revision number.

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 OPERATING INSTRUCTIONS 32
Engine Diagnostic Codes:  Failure Flashes can be read on the Engine Failure Lamp when the
on/off power switch is ‘ON’ or when the unit is running.

 The Engine Failure Lamp is located behind the front end panel (see
figure).

 The Failure Lamp is luminated for 2 seconds when the ECU is

powered on.

 A lamp flash duration of 0.5 second is a ‘Short’ flash.

 A lamp flash duration of 1.5 seconds is a ‘Long’ flash.

 A failure flash sequence of ‘1 Long and 3 Short’ would be displayed

by flashing the lamp one time with a duration of 1.5 seconds and three
times with a duration of 0.5 seconds.

 When two or more failures have occurred simultaneously, the failure

lamp will pause for 3 seconds between flash sequences.

 Failure flash sequences continuously repeat with 3 second pauses

between flash sequences until the failure is corrected.

A. − Engine Failure Lamp

Failure Failure Flashes Remark

Coolant temperature sensor failure 4 Short

Speed sensor failure 6 Short

Rack position sensor failure 7 Short

Rack actuator failure 8 Short

EGR valve failure 1 Long and 3 Short

CSD solenoid valve failure 1 Long and 4 Short

Main relay failure 1 Long and 6 Short

Rack actuator relay failure 1 Long and 7 Short

ECU temperature alarm 2 Long and 5 Short ECU temp > 221F

Coolant temperature alarm 3 Long and 6 Short Coolant temp > 230F

ECU failure 4 Long and 1 Short

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33 MAINTENANCE

MAINTENANCE SCHEDULE
Initial 500 Daily Weekly Monthly 3 Monthly. 6 Monthly. 12 Monthly.
miles 250 hrs. 500 hrs 1000 hrs
/850 km

Compressor Oil Level C

Engine Oil Level C
*Radiator Coolant Level C
Gauges/Lamps C
*Air Cleaner Service Indicators C
Fuel Tank (Fill at end of day) C D
*Fuel/Water Separator Drain C
Oil Leaks C
Fuel Leaks C
Drain Water From Fuel Filters D
Coolant Leaks C
Radiator Filler Cap C
Air Cleaner Precleaner Dumps C
Fan/Alternator Belts C
Generator Drive Belt C
Battery Connections/Electrolyte C
Tire Pressure and Surface C
*Wheel Lug Nuts C
Hoses (Oil, Air, Intake, etc.) C
Automatic Shutdown System C
Air Cleaner System C
Compressor Oil Cooler Exterior C
*Engine Rad/Oil Cooler Exterior C
Fasteners, Guards C
Air Cleaner Elements R/WI

*Disregard if not appropriate for this particular machine. D = Drain

(1) or 3000 miles/5000km whichever is the sooner G = Grease
(2) or as defined by local or national legislation R=Replace
C = Check (adjust, clean or replace as necessary) T = Test
CBT =check before towing. W I =or when indicated if earlier.
CR = Check and report Refer to specific sections of the operator’s manual for more
information.

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 MAINTENANCE 34
Initial 500 Daily Weekly Monthly 3 Monthly. 6 Monthly. 12 18
miles 250 hrs. 500 hrs Monthly. Monthly.
/850 km
1000 hrs 1500 hrs

*Fuel/Water Separator Element R

Compressor Oil Filter Element R
Compressor Oil R
Engine Oil Change R
Engine Oil Filter R
*Water Pump Grease. R
*Wheels (Bearings, Seals, etc.) C
*Engine Coolant C R
Fuel Filter Element R
*Injection Nozzle Check C
Shutdown Switch Settings T
Scavenger Orifice & Related Parts C
Oil Separator Element R
*Feed Pump Strainer Cleaning. C
Coolant Replacement R
*Valve Clearance Check C
Lights (running, brake, & turn) CBT
Pintle Eye Bolts CBT
*Brakes C C
*Brake linkage C
Emergency stop T
Fasteners C
Running gear linkage G
Safety valve C
Running gear bolts(1) C

*Disregard if not appropriate for this particular machine. D = Drain

(1) or 3000 miles/5000km whichever is the sooner G = Grease
(2) or as defined by local or national legislation
R=Replace
C = Check (adjust, clean or replace as necessary)
T = Test
CBT =check before towing.
W I =or when indicated if earlier.
CR = Check and report
Refer to specific sections of the operator’s manual for more
information.

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35 MAINTENANCE
Initial 500 Daily Weekly Monthly 3 Monthly. 6 Monthly. 12 Monthly.
miles 250 hrs. 500 hrs 1000 hrs
/850 km

Scavenge line C
Pressure system C
Engine breather element C
Pressure gauge C
Pressure regulator C
Separator tank (2) exterior CR
Lubricator (Fill) C

2 Yrs 4 Yrs 6 Yrs

Safety valve C
Hoses R
Separator tank (2) interior C

*Disregard if not appropriate for this particular machine. D = Drain

(1) or 3000 miles/5000km whichever is the sooner G = Grease
(2) or as defined by local or national legislation R=Replace
C = Check (adjust, clean or replace as necessary) T = Test
CBT =check before towing. W I =or when indicated if earlier.
CR = Check and report Refer to specific sections of the operator’s manual for more
information.

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ROUTINE MAINTENANCE
This section refers to the various components which require
periodic maintenance and replacement.
The SERVICE/MAINTENANCE CHART indicates the various
components’ descriptions and the intervals when maintenance has to
take place. Oil capacities, etc., can be found in the GENERAL
INFORMATION section of this manual.
For any specification or specific requirement on service or
preventative maintenance for the engine, refer to the Engine
Manufacturer’s Manual.
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the
system and that the machine cannot be started accidentally.
If the automatic blowdown fails to operate, then pressure must be
gradually relieved by operating the manual blowdown valve. Suitable
personal protective equipment should be worn.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
Prior to attempting any maintenance work, ensure that:−
. all air pressure is fully discharged and isolated from the system. If
the automatic blowdown valve is used for this purpose, then allow
enough time for it to complete the operation.
. the discharge pipe / manifold area is depressurised by opening the
discharge valve, whilst keeping clear of any airflow from it.
MINIMUM PRESSURE VALVE − WHEN FITTED
NOTE: Pressure will always remain in the part of the system between
the minimum pressure valve and the discharge valve after operation of
the auto blowdown valve.
This pressure must be relieved by carefully:
(a) Disconnecting any downstream equipment.
(b) Opening the discharge valve to atmosphere.
(Use hearing protection if necessary).
. the machine cannot be started accidentally or otherwise, by posting
warning signs and/or fitting appropriate anti−start devices.
. all residual electrical power sources (mains and battery) are
isolated.
Prior to opening or removing panels or covers to work inside
a machine, ensure that:−
. anyone entering the machine is aware of the reduced level of
protection and the additional hazards, including hot surfaces and
intermittently moving parts.
. the machine cannot be started accidentally or otherwise, by posting
warning signs and/or fitting appropriate anti−start devices.
Prior to attempting any maintenance work on a running
machine, ensure that:−
. the work carried out is limited to only those tasks which require the
machine to run.
MAINTENANCE 36
. the work carried out with safety protection devices disabled or
removed is limited to only those tasks which require the machine to be
running with safety protection devices disabled or removed.
. all hazards present are known (e.g. pressurised components,
electrically live components, removed panels, covers and guards,
extreme temperatures, inflow and outflow of air, intermittently moving
parts, safety valve discharge etc.).
. appropriate personal protective equipment is worn.
. loose clothing, jewelry, long hair etc. is made safe.
. warning signs indicating that Maintenance Work is in Progress are
posted in a position that can be clearly seen.
Upon completion of maintenance tasks and prior to returning
the machine into service, ensure that:−
. the machine is suitably tested.
. all guards and safety protection devices are refitted.
. all panels are replaced, canopy and doors closed.
. hazardous materials are effectively contained and disposed of.
PROTECTIVE SHUTDOWN SYSTEM
Comprises:
. Low engine oil pressure switch
. High discharge air temperature switch
. High engine water temperature switch
. Alternator/drive belt failure circuit.
. Low engine fuel level switch.
Low engine oil pressure switch.
At three month intervals, test the engine oil pressure switch circuit
as follows:
. Start the machine.
NOTE: Do not press the load button.
. Remove a wire from one terminal of the switch. The machine should
shutdown.
At twelve month intervals, test the engine oil pressure switch as
follows:
. Remove the switch from the machine.
. Connect it to an independent low pressure supply (either air or oil).
. The switch should operate at 1,0 bar.
. Refit the switch.
Temperature switch(es).
At three month intervals, test the temperature switch circuit(s) as
follows:
. Start the machine.
NOTE: Do not press the load button.
. Disconnect each switch in turn. The machine should shutdown.
. Re−connect the switch.
7/51, 7/71, 12/56
37 MAINTENANCE
High discharge air temperature switch(es).
At twelve month intervals, test the air discharge temperature
switch(es) by removing it from the machine and immersing in a bath
of heated oil. The switch should operate at 120C. Refit the switch.
High water temperature switch
At twelve month intervals, test the water temperature switch by
removing it from the machine and immersing in a bath of heated
oil. The switch should operate at 105C. Refit the switch.
Alternator/drive belt failure circuit.
At twelve month intervals test the alternator drive belt failure circuit
as follows:
. Remove the drive belt from the machine.
. Turn the key switch to position 1, the alternator charge light will il-
luminate.
. Turn the key switch to position 3 (engine start position).
. The machine should shutdown when the key switch is returned to
position 1.
Low engine fuel level switch.
At three month intervals, test the low engine fuel level switch circuit
as follows:
. Start the machine.
NOTE: Do not press the load button.
. Disconnect the switch, the machine should shutdown.
. Re−connect the switch.
At twelve month intervals, test the low engine fuel level switch by
removing and operating the float manually.
CAUTION: Never remove or replace switches when the machine
is running.
SCAVENGE LINE
The scavenge line runs from the combined orifice/drop tube in the
separator tank, to the orifice fitting located in the airend.
Examine the orifice, check valve and hoses at every service or in
the event of oil carryover into the discharge air.
It is good preventative maintenance to check that the scavenge line
and tube are clear of any obstruction each time the compressor
lubricant is changed as any blockage will result in oil carryover into the
discharge air.
COMPRESSOR OIL FILTER
Refer to the MAINTENANCE CHART in this section for the
recommended servicing intervals.
Removal
WARNING: Do not remove the filter(s) without first making sure
that the machine is stopped and the system has been completely
relieved of all air pressure. (Refer to STOPPING THE UNIT in the
OPERATING INSTRUCTIONS section of this manual).
7/51, 7/71, 12/56
Clean the exterior of the filter housing and remove the spin−on
element by turning it in a counter−clockwise direction.
Inspection
Examine the filter element.
CAUTION: If there is any indication of the formation of varnishes,
shellacs or lacquers on the filter element, it is a warning that the
compressor lubricating and cooling oil has deteriorated and that it
should be changed immediately. Refer to LUBRICATION later in this
section.
Reassembly
Clean the filter gasket contact area and install the new element by
screwing in a clockwise direction until the gasket makes contact with
the filter housing. Tighten a further 1/2 to 3/4 of a revolution.
CAUTION: Start the machine (refer to PRIOR TO STARTING and
STARTING THE UNIT in the OPERATING INSTRUCTIONS section
of this manual) and check for leakage before the machine is put back
into service.
COMPRESSOR OIL SEPARATOR ELEMENT
Normally the separator element will not require periodic
maintenance provided that the air and oil filter elements are correctly
maintained.
If, however, the element has to be replaced, then proceed as
follows:
Removal
WARNING: Do not remove the filter(s) without first making sure
that the machine is stopped and the system has been completely
relieved of all air pressure. (Refer to STOPPING THE UNIT in the
OPERATING INSTRUCTIONS section of this manual).
Disconnect all hoses and tubes from the separator tank cover plate.
Remove the drop−tube from the separator tank cover plate and then
remove the cover plate. Remove the separator element.
Inspection
Examine the filter element. Examine all hoses and tubes, and
replace if necessary.
Reassembly
Thoroughly clean the orifice/drop tube and filter gasket contact area
before reassembly. Install the new element.
WARNING
Do not remove the staple from the anti−static gasket on the
separator element since it serves to ground any possible static
build−up. Do not use gasket sealant since this will affect electrical
conductance.
 MAINTENANCE 38
Reposition the cover plate, taking care not to damage the gasket, Reassembly
and replace the cover plate screws tightening in a criss−cross pattern
to the recommended torque (refer to the TORQUE SETTING TABLE Assemble the new element into the filter housing ensuring that the
later in this section). seal seats properly.

Engage the adaptor in the cover plate with the drop−tube integral Reset the restriction indicator by depressing the rubber diaphragm.
with the filter, reconnect all hoses and tubes to the separator tank cover
plate.
Assemble the dust collector box parts, ensuring that they are
correctly positioned.
Replace the compressor oil (refer to LUBRICATION later in this
section).
Before restarting the machine, check that all clamps are tight.

CAUTION: Start the machine (refer to PRIOR TO STARTING and

VENTILATION
STARTING THE UNIT in the OPERATING INSTRUCTIONS section
of this manual) and check for leakage before the machine is put back Always check that the air inlets and outlets are clear of debris etc.
into service.

CAUTION: NEVER clean by blowing air inwards.

COMPRESSOR OIL COOLER AND ENGINE RADIATOR
When grease, oil and dirt accumulate on the exterior surfaces of the oil
cooler and radiator, the efficiency is impaired. It is recommended that
each month the oil cooler and radiator be cleaned by directing a jet of
compressed air, (carrying if possible a non−flammable cleaning
solvent) over the exterior core of the cooler/radiator. This should
remove any accumulation of oil, grease and dirt from the exterior core
of the cooler so that the entire cooling area can radiate the heat of the
lubricating and cooling oil/water into the air stream.
COOLING FAN DRIVE
Periodically check that the fan mounting bolts in the fan hub have
not loosened. If, for any reason, it becomes necessary to remove the
fan or re−tighten the fan mounting bolts, apply a good grade of
commercially available thread locking compound to the bolt threads
and tighten to the torque value shown in the TORQUE SETTING
TABLE later in this section.

WARNING: Hot engine coolant and steam can cause injury. When
adding coolant or antifreeze solution to the engine radiator, stop
the engine at least one minute prior to releasing the radiator filler
cap. Using a cloth to protect the hand, slowly release the filler cap,
absorbing any released fluid with the cloth. Do not remove the
filler cap until all excess fluid is released and the engine cooling
system fully depressurised.
WARNING: Follow the instructions provided by the antifreeze
supplier when adding or draining the antifreeze solution. It is
advisable to wear personal protective equipment to prevent skin
and eye contact with the antifreeze solution.
AIR FILTER ELEMENTS
The air filter should be inspected regularly (refer to the
SERVICE/MAINTENANCE CHART) and the element replaced when
the restriction indicator shows red or every 6 Months (500 hours),
whichever comes first. The dust collector box(es) should be cleaned
daily (more frequently in dusty operating conditions) and not allowed to
become more than half full.
The fan belt(s) should be checked regularly for wear and correct
tensioning.
FUEL SYSTEM
The fuel tank should be filled daily or every eight hours. To minimise
condensation in the fuel tank(s), it is advisable to top up after the
machine is shut down or at the end of each working day. At six month
intervals drain any sediment or condensate that may have
accumulated in the tank(s).
FUEL FILTER WATER SEPARATOR
If the fuel filter water separator contains a filter element it should be
replaced at regular intervals (see the SERVICE/MAINTENANCE
CHART).
HOSES
All components of the engine cooling air intake system should be
checked periodically to keep the engine at peak efficiency.

Removal At the recommended intervals, (see the

CAUTION: Never remove and replace element(s) when the machine
is running.
Clean the exterior of the filter housing and remove the filter element
by releasing the nut.
SERVICE/MAINTENANCE CHART), inspect all of the intake lines to
the air filter, and all flexible hoses used for air lines, oil lines and fuel
lines.
Periodically inspect all pipework for cracks, leaks, etc. and replace
immediately if damaged.
ELECTRICAL SYSTEM

Inspection WARNING: Always disconnect the battery cables before

Check for cracks, holes or any other damage to the element by performing any maintenance or service.
holding it up to a light source, or by passing a lamp inside.

Check the seal at the end of the element and replace if any sign of
damage is evident.

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39 MAINTENANCE
Inspect the safety shutdown system switches and the instrument
panel relay contacts for evidence of arcing and pitting. Clean where
necessary.

Check the mechanical action of the components.

Check the security of electrical terminals on the switches and relays

i.e. nuts or screws loose, which may cause local hot spot oxidation.

Inspect the components and wiring for signs of overheating i.e.

discolouration, charring of cables, deformation of parts, acrid smells
and blistered paint.

BATTERY
Keep the battery terminals and cable clamps clean and lightly 1 Handbrake lever
coated with petroleum jelly to prevent corrosion. 2 Draw bar and bellows
3 Handbrake lever pivot
The retaining clamp should be kept tight enough to prevent the
battery from moving. 4 Transmission lever
5 Brake cable
PRESSURE SYSTEM
6 Breakaway Cable
At 500 hour intervals it is necessary to inspect the external surfaces
of the system (from the airend through to the discharge valve(s))
including hoses, tubes, tube fittings and the separator tank, for visible Requirements:
signs of impact damage, excessive corrosion, abrasion, tightness and
During the adjustment procedure always start with the wheel brakes.
chafing. Any suspect parts should be replaced before the machine is
put back into service. Always rotate the wheel in the direction of forward movement.
Ensure that an M10 safety screw is fitted to the handbrake pivot.
TYRES/TYRE PRESSURE
The brake actuators must not be pre−tensioned − if necessary loosen
See the GENERAL INFORMATION section of this manual. the brake linkage [7] on the brake equalisation assembly [8].
Check that brake actuators and cables [11] operate smoothly.
RUNNING GEAR/WHEELS
Check the wheel nut torque 20 miles (30 kilometres) after refitting
the wheels. Refer to the TORQUE SETTING TABLE later in this
section.

Lifting jacks should only be used under the axle.

The bolts securing the running gear to the chassis should be

checked periodically for tightness (refer to the
SERVICE/MAINTENANCE CHART for frequency) and re−tightened
where necessary. Refer to the TORQUE SETTING TABLE later in this
section.

BRAKES
Check and adjust the brake linkage at 500 miles (850Km) then 7 Brake linkage
every 3000 miles (5000Km) or 3 months (whichever is the sooner) to
compensate for any stretch of the adjustable cables. Check and adjust 8 Equalisation assembly
the wheel brakes to compensate for wear.
9 Compression spring
10 Equaliser plate
Adjusting the overrun braking system (KNOTT 11 Cable
Running Gear)
1: Preparation CAUTION
The compression spring [9] must only be lightly pre−tensioned and
Jack up the machine when operating must never touch the axle tube.
Never adjust the brakes at the brake linkage [7].
Disengage the handbrake lever [1].
Fully extend the draw bar [2] on the overrun braking system.

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2. Brake Shoe Adjustment
12 Adjusting screw
13 Cable entry
Width across flats of adjusting screw [12]
Brake size Key width
160x35 / 200x50 SW 17
250x40 SW 19
300x60 SW 22
Tighten adjusting screw [12] clockwise until the wheel locks.
Loosen adjusting screw [12] anti−clockwise (approx. ½ turn) until the
wheel can be moved freely.
Slight dragging noises that do not impede the free movement of the
wheel are permissible.
This adjustment procedure must be carried out as described on both
wheel brakes.
When the brake has been adjusted accurately the actuating distance
is approximately 5−8mm on the cable [11]
3: Compensator assembly adjustment
Variable Height models
Fit an M10 safety screw to the handbrake pivot.
Disconnect the handbrake cable [5] at one end.
Pre−adjust brake linkage [7] lengthways (a little play is permissible) and
re−insert the cable [5], adjusting it to give a small amount of play.
Remove the M10 safety screw from the handbrake pivot.
All Models
Engage the handbrake lever [1] and check that the position of the
equaliser plate [10] is at right angles to the pulling direction. If
necessary correct the position of the equaliser plate [10] on the cables
[11].
The compression spring [9] must only be slightly pre−tensioned and
when engaged must not touch the axle tube.
4: Brake linkage adjustment
Adjust the brake linkage [7] lengthways without pre−tension and
without play in the transmission lever [4].
Readjustment
Engage the handbrake lever [1] forcefully a number of times to set the
brake.
Check the alignment of the equalisation assembly [8], this should be at
right angles to the pulling direction
Check the play in the brake linkage [7]
If necessary adjust the brake linkage [7] again without play and without
pre−tensioning
There must still be a little play in cable [5] (Variable Height Only)
MAINTENANCE 40
Check the position of the hand brake lever [1]. The start of resistance
should be approximately 10−15mm above the horizontal position.
Check that the wheels move freely when the handbrake is disengaged.
Final test
Check the fastenings on the transmission system (cables, brake
equalisation system and linkage).
Check the handbrake cable [5] for a small amount of play and adjust if
necessary (Variable height only)
Check the compression spring [9] for pre−tensioning.
Test run
If necessary carry out 2−3 test brake actions.
Test brake action
Check the play in brake linkage [7] and if necessary adjust the length
of brake linkage [7] until there is no play.
Apply the handbrake while rolling the machine forward, travel of the
handbrake lever up to 2/3 of maximum is allowed.
Re−adjusting the overrun braking system (KNOTT
Running Gear)
Re−adjustment of the wheel brakes will compensate for brake lining
wear. Follow the procedure described in 2: Brake Shoe Adjustment.
Check the play in the brake linkage [7] and re−adjust if necessary.
Important
Check the brake actuators and cables [11]. The brake actuators must
not be pre−tensioned.
Excessive operation of the handbrake lever, which may have been
caused by worn brake linings, must not be corrected by re−adjusting
(shortening) the brake linkage [7]
Re−adjustment
The handbrake lever [1] should be engaged forcefully several times to
set the braking system.
Check the setting of the brake equalisation assembly [8], which should
be at right angles to the pulling direction.
Check the play in the brake linkage [7] again, ensuring that there is no
play in the brake linkage and that it is adjusted without pre−tension
Check the position of the hand brake lever [1], cable [5] (with little play)
and the compression spring [9] (only slight pre−tension). The start of
resistance of the handbrake lever should be approximately 10−15mm
above the horizontal position.
Final test
Check the fastenings on the transmission system (cables, brake
equalisation system and linkage)
Apply the handbrake while rolling the machine forward, travel of the
handbrake lever up to 2/3 of maximum is allowed.
Check the handbrake cable [5] for a small amount of play and adjust if
necessary (Variable height only)
Check the compression spring [9] for slight pre−tensioning.
CAUTION: Check the wheel nut torque 20 miles (30 kilometres) after
refitting the wheels (Refer to the TORQUE SETTING TABLE later in
this section).
7/51, 7/71, 12/56
41 MAINTENANCE
LUBRICATION WARNING: DO NOT, under any circumstances, remove any drain
plugs or the oil filler plug from the compressor lubricating and
The engine is initially supplied with engine oil sufficient for a nominal cooling system without first making sure that the machine is
period of operation (for more information, consult the Engine section of stopped and the system has been completely relieved of all air
this manual). pressure (refer to STOPPING THE UNIT in the OPERATING
INSTRUCTIONS section of this manual).

CAUTION: Always check the oil levels before a new machine is put into
service. Completely drain the receiver/separator system including the piping
and oil cooler by removing the drain plug(s) and collecting the used oil
in a suitable container.
If, for any reason, the unit has been drained, it must be re−filled with
new oil before it is put into operation. Replace the drain plug(s) ensuring that each one is secure.

ENGINE LUBRICATING OIL

The engine oil should be changed at the engine manufacturer’s NOTE: If the oil is drained immediately after the machine has been
recommended intervals. Refer to the Engine section of this manual. running, then most of the sediment will be in suspension and will
therefore drain more readily.

ENGINE LUBRICATING OIL SPECIFICATION CAUTION: Some oil mixtures are incompatible and result in the
Refer to the Engine section of this manual. formation of varnishes, shellacs or lacquers which may be insoluble.

ENGINE OIL FILTER ELEMENT NOTE: Always specify INGERSOLL−RAND Pro−TecTM oil for use
at all ambient temperatures above −23C.
The engine oil filter element should be changed at the engine
manufacturer’s recommended intervals. Refer to the Engine section of
this manual.
COMPRESSOR OIL FILTER ELEMENT
COMPRESSOR LUBRICATING OIL
Refer to the SERVICE / MAINTENANCE CHART in this section for
Refer to the SERVICE/MAINTENANCE CHART in this section for service intervals.
service intervals.

RUNNING GEAR WHEEL BEARINGS

NOTE: If the machine has been operating under adverse conditions, Wheel bearings should be packed with grease every 6 months. The
or has suffered long shutdown periods, then more frequent service type of grease used should conform to specification MIL−G−10924.
intervals will be required.

7/51, 7/71, 12/56

 MAINTENANCE 42

SPEED AND PRESSURE REGULATION ADJUSTMENT The unit should speed up and then unload (and drop back to IDLE).
With the unit unloaded (service valve is fully closed), turn the adjusting
Normally, regulation requires no adjusting, but if correct adjustment screw on the pressure regulator clockwise until the discharge pressure
is lost, proceed as follows: gauge indicates 8.6 bar (7/51, 7/71) or 13 bar (12/56).

Refer to the diagram above.

Open the service valve fully. Check the engine speed up to full RPM,
then adjust the service valve to maintain 7 bar (7/51, 7/71) or 12 bar
1: Pressure transducer (12/56) − see pressure gauge on the control panel.
2: Adjusting screw
B: Push After Warm−up button
If the engine speed falls down before 7 bar (7/51, 7/71) or 12 bar
(12/56) pressure is attained, then turn the adjusting screw clockwise to
At the Pressure Regulator loosen the jam nut and turn screw increase the pressure. Optimum adjustment is achieved when the
counterclockwise until tension is no longer felt at the screw. Then, turn engine speed just falls down from full speed and the pressure gauge
screw clockwise one full turn. reads 7.2 bar (7/51, 7/71) or 12.2 bar (12/56).

Close the service valve. Lock adjusting screw by the jam nut.

Start the machine (Refer to STARTING INSTRUCTIONS in the Close the service valve. The engine will slow to idle speed.
OPERATING INSTRUCTIONS section of this manual).

Press button (B) − Push After Warm−up (Refer to STARTING CAUTION: Never allow the idle pressure to exceed 8,6bar (7/51, 7/71)
INSTRUCTIONS in the OPERATING INSTRUCTIONS section of this or 13 bar (12/56) on the pressure gauge, otherwise the safety valve will
manual) when fitted (standard for 7/71, 12/56, optional for 7/51). operate.

7/51, 7/71, 12/56

43 MAINTENANCE
TORQUE VALUES

ft lbf Nm ft lbf Nm
Airend to engine 29−35 39−47 Fan guard 9−11 12−15

Air filter to bracket 16−20 22−27 Fan to hub 12−15 16−20

Autella clamp to exhaust 9−11 12−15 Lifting bail bracket to engine 29−35 39−47

Baffle to frame 9−11 12−15 Oil pipe (−12jic) 71−88 96−119

Blowdown solenoid valve 21−26 28−35 Radiator/Cooler to baffle 9−11 12−15

Discharge manifold to frame 29−35 39−47 Running gear front to chassis 63−69 82−93

Drive pins to engine flywheel 57−69 77−93 Running gear rear to chassis 63−69 82−93

Drop Leg 53−63 72−85 Running gear drawbar to axle 29−35 39−47

Engine/airend to chassis 54−58 73−78 Separator tank cover 40−50 54−68

Euro−Loc adaptor to separator tank 58−67 78−91 Separator tank to frame 18−22 24−30

Exhaust flange to manifold 17−21 23−28 Service pipe (−20jic) 106−133 143−180

Sight glass 40−50 54−68

Wheel nuts 62−70 85−95

7/51, 7/71, 12/56

 MAINTENANCE 44
COMPRESSOR LUBRICATION
RATED OPERATING PRESSURE
Portable Compressor Fluid Chart 100 − 300 PSI 350 PSI 500 PSI
125F
Refer to these charts for correct compressor fluid required. Note 50C
that the selection of fluid is dependent on the design operating
40C 104F IR IR IR
pressure of the machine and the ambient temperature expected to XHP505 XHP 1001 XHP1001
be encountered before the next oil change. 30C 86F

Design Operating Ambient 20C 65F

Specification IR
PRO−TEC

Pressure Temperature
IR 10C 50F
100 psi to 300 psi −10F to 125F IR Pro−Tec
PER FORMANCE
(−23C to 52C) Mil –PRF 2104G 500 0C 32F IR IR
PERFORMANCE
SAE 10W 500
XHP505

100 psi to 300 psi −40F to 125F IR Performance 500 −10C 14F
(−40C to 52C) Mil−L−46167 10F
−20C
350 psi −10F to 125F IR XHP 505
−10F
(−23C to 52C)
−30C −22F
65F to 125F (18C IR XHP1001
to 52C)
−40C −40F
−40F to 65F IR Performance 500 consult
(−40C to 18C) Mil−L−46167
factory
500 psi 50F to 125F (10C IR XHP1001
to 52C)
10F to 65F (−12C IR XHP 505
to 18C) Recommended Ingersoll−Rand Fluids − Use of these fluids with
below 10F (−12C) Consult Factory original IR filters can extend airend warranty. Refer to operator’s
manual warranty section for details or contact your IR
representative.

Recommended Fluid 3.8 Litre 19.0 Litre 208.2 Litre

IR Pro−Tec
36899698 36899706 36899714

IR XHP 505 35365188 35365170

IR Performance 500 35382928 35382936 35382944

IR XHP1001 35612738 35300516

7/51, 7/71, 12/56

45 ELECTRICAL SYSTEM
7/51

7/51, 7/71, 12/56

 ELECTRICAL SYSTEM 46
7/51

7/51, 7/71, 12/56

47 ELECTRICAL SYSTEM
KEY

B1 Engine Starter P4 Rack Actuator

B2 Fuel Lift Pump P5 Speed Sensor
BAT1 Battery 12VDC P6 Engine Coolant Temperature Sensor
DS1 Engine Diagnostic Lamp P7 Cold Start Device Solenoid
DS2 Low Fuel Lamp P8/TR1 CAN BUSS Terminating Resistor
DS3 No Charge Lamp P9/TR2 CAN BUSS Terminating Resistor
F1 Main Fuse P10 Engine ECU Interface Communication Connector
F2 Engine ECU Fuse PB1 Push After Warm up Button (Option on 7/51, standard on
7/71, 12/56)
G1 Engine Alternator
PS1 Regulation System Pressure Sensor
HR1 Engine Inlet Heater
S1 Keyswitch
J14 Communication Connector
S2 Separator Temperature Switch
K1 Engine Starter Relay
S3 Airend Discharge Temperature Switch
K2 Inlet Heater Relay
S4 Engine Coolant temperature switch
K3 Engine ECU Power Relay
S5 Engine Oil Pressure Switch
K4 Rack Actuator Relay
SV1 Generator Contactor
K5 Low Fuel Relay
SV2 Push After Warm up Solenoid (Option on 7/51, standard
M1 Hourmeter
on 7/71, 12/56)
P1 SECU − Small Electronic Control Unit
SV3 Generator Enable Switch (Option)
P2 Yanmar Engine ECU
SV4 Emergency Stop Button (Option)
P3 EGR Valve
U1 Low Fuel Shutdown Switch

7/51, 7/71, 12/56

 ELECTRICAL SYSTEM 48
7/71, 12/56

7/51, 7/71, 12/56

49 ELECTRICAL SYSTEM
7/71, 12/56

7/51, 7/71, 12/56

 ELECTRICAL SYSTEM 50
KEY

B1 Engine Starter P4 Rack Actuator

B2 Fuel Lift Pump P5 Speed Sensor
BAT1 Battery 12VDC P6 Engine Coolant Temperature Sensor
DS1 Engine Diagnostic Lamp P7 Cold Start Device Solenoid
DS2 Low Fuel Lamp P8/TR1 CAN BUSS Terminating Resistor
DS3 No Charge Lamp P9/TR2 CAN BUSS Terminating Resistor
F1 Main Fuse P10 Engine ECU Interface Communication Connector
F2 Engine ECU Fuse PB1 Push After Warm up Button (Option on 7/51, standard on
7/71, 12/56)
G1 Engine Alternator
PS1 Regulation System Pressure Sensor
HR1 Engine Inlet Heater
S1 Keyswitch
J14 Communication Connector
S2 Separator Temperature Switch
K1 Engine Starter Relay
S3 Airend Discharge Temperature Switch
K2 Inlet Heater Relay
S4 Engine Coolant temperature switch
K3 Engine ECU Power Relay
S5 Engine Oil Pressure Switch
K4 Rack Actuator Relay
SV1 Generator Contactor
K5 Low Fuel Relay
SV2 Push After Warm up Solenoid (Option on 7/51, standard
M1 Hourmeter
on 7/71, 12/56)
P1 SECU − Small Electronic Control Unit
SV3 Generator Enable Switch (Option)
P2 Yanmar Engine ECU
SV4 Emergency Stop Button (Option)
P3 EGR Valve
U1 Low Fuel Shutdown Switch

7/51, 7/71, 12/56

51 ELECTRICAL SYSTEM
SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM − 7 PINS

KEY

IL LH Indicator light − left hand B Black

IL RH Indicator light − right hand G Green
FL Fog light K Pink
SL LH Stop light − left hand N Brown
SL RH Stop light − right hand O Orange
TL LH Tail light − left hand P Purple
TL RH Tail light − right hand R Red
PL Plug S Grey
U Blue
W White
Y Yellow

7/51, 7/71, 12/56

 ELECTRICAL SYSTEM 52
SCHEMATIC DIAGRAM FOR EUROPEAN CE LIGHTING SYSTEM − 13 PINS REVERSE LIGHT

KEY

IL LH Indicator light − left hand B Black

IL RH Indicator light − right hand G Green
FL Fog light K Pink
RL Reverse light N Brown
SL LH Stop light − left hand O Orange
SL RH Stop light − right hand P Purple
TL LH Tail light − left hand R Red
TL RH Tail light − right hand S Grey
PL Plug U Blue
W White
Y Yellow

7/51, 7/71, 12/56

53 PIPING AND INSTRUMENTATION SYSTEM

KEY

1 Air discharge 8 Oil cooler

2 Sonic orifice (restricts flow) 9 Oil filter
3 Pressure gauge 10 Thermostatic valve (Where fitted)
4 Separator tank
5 Safety valve Air
6 Compressor Oil
7 Engine Air/oil

7/51, 7/71, 12/56

 FAULT FINDING 54
FAULT CAUSE REMEDY FAULT CAUSE REMEDY
Engine fails Low battery Check the fan belt tension, battery Engine Incorrect Check the throttle setting.
to start. charge. and cable connections. speed too throttle arm
low. setting.
Bad earth Check the earth cables, clean as
connection. required. Blocked fuel Check and replace if necessary.
filter.
Loose Locate and make the connection
connection. good. Blocked air Check and replace the element if
filter. necessary.
Fuel Check the fuel level and fuel
starvation. system components. Replace the Faulty Check the regulation system.
fuel filter if necessary. regulator
valve.
Relay failed. Replace the relay.
Premature Check the regulation and the
Engine control Check the pressure transducer. unloading. operation of the pressure
not in ’run’ transducer.
position.
Excessive Engine speed See ”Engine speed too low”
Engine Electrical fault Test the electrical circuits. vibration. too low.
starts but
stalls when Low engine oil Check the oil level and the oil
the switch pressure. filter(s).
returns to Faulty relay Check the relays. Refer also to the engine section of this manual and the engine
position I. diagnostic codes.
Faulty Check the key−switch.
key−switch
Engine Electrical fault. Test the electrical circuits. Air Engine speed Check the pressure transducer
starts but discharge too low. and air filter(s).
will not run Low engine oil Check the oil level and oil filter(s). capacity too
or engine pressure. low. Blocked air Check the restriction indicators and
shuts down cleaner. replace the element(s) if
Safety Check the safety shut-down necessary.
prematurely. shut-down switches.
system in High pressure Check for leaks.
operation. air escaping.
Fuel Check the fuel level and fuel Incorrectly set Reset the regulation system. Refer
starvation. system components. Replace the regulation to SPEED AND PRESSURE
fuel filter if necessary. system. REGULATION ADJUSTMENT in
the MAINTENANCE section of this
Switch failure. Test the switches. manual.
High Check the compressor oil level and Compressor Low oil level. Top up the oil level and check for
compressor oil oil cooler. Check the fan drive. overheats. leaks.
temperature.
Dirty or Clean the oil cooler fins.
Water present Check the water separator and blocked oil
in fuel system. clean if required. cooler.
Faulty relay. Check the relay in the holder and Incorrect Use Ingersoll−Rand
replace if necessary. grade of oil. recommended oil.
Engine Reduced Check the fan and the drive belts. Recirculation Move the machine to avoid
Overheats. cooling air Check for any obstruction inside of cooling air. recirculation.
from fan. the cowl.
Faulty Check the operation of the switch
Engine Faulty Check the regulation system. temperature and replace if necessary.
speed too regulator switch.
high. valve.
Reduced Check the fan and the drive belts.
cooling air Check for any obstruction inside
from fan. the fan cowl.
Excessive oil Blocked Check the scavenge line, drop tube
present in scavenge line. and orifice. Clean and replace.
the
discharge Perforated Replace the separator element.
air. separator
element.
Pressure in Check the minimum pressure valve
the system is or sonic orifice.
too low.

7/51, 7/71, 12/56

55 FAULT FINDING
FAULT CAUSE REMEDY FAULT CAUSE REMEDY
Safety valve Operating Check the setting and operation of Oil is forced Incorrect Always employ the correct
operates. pressure too the regulator valve piping. back into the stopping stopping procedure. Close the
high. air filter. procedure discharge valve and allow the
used machine to run on idle before
Incorrect Adjust the regulator. stopping.
setting of the
regulator. Faulty inlet Check for free operation of the inlet
valve. valve(s).
Faulty Replace the regulator.
regulator. Faulty Remove the valve from the
discharge discharge pipe and check the
Inlet valve set Refer to SPEED AND PRESSURE check valve. operation.
incorrectly. REGULATION ADJUSTMENT in
the MAINTENANCE section of this Machine Inlet valve set Refer to SPEED AND PRESSURE
manual. goes to full incorrectly. REGULATION ADJUSTMENT in
pressure the MAINTENANCE section of this
Loose Check all pipe/hose connections. when manual.
pipe/hose started.
connections.
Faulty safety Check the relieving pressure. Machine fails Faulty load Replace the solenoid. Check the
valve. Replace the safety valve if faulty. to load when solenoid. electrical circuit by feeling for
DO NOT ATTEMPT A REPAIR. the load movement whilst depressing the
button is load button.
pressed.

7/51, 7/71, 12/56

 FAULT FINDING 56
Engine Diagnostic Codes:  Failure Flashes can be read on the Engine Failure Lamp when the
on/off power switch is ‘ON’ or when the unit is running.

 The Engine Failure Lamp is located behind the front end panel (see
figure).

 The Failure Lamp is luminated for 2 seconds when the ECU is

powered on.

 A lamp flash duration of 0.5 second is a ‘Short’ flash.

 A lamp flash duration of 1.5 seconds is a ‘Long’ flash.

 A failure flash sequence of ‘1 Long and 3 Short’ would be displayed

by flashing the lamp one time with a duration of 1.5 seconds and three
times with a duration of 0.5 seconds.

 When two or more failures have occurred simultaneously, the failure

lamp will pause for 3 seconds between flash sequences.

 Failure flash sequences continuously repeat with 3 second pauses

between flash sequences until the failure is corrected.

A. − Engine Failure Lamp

Failure Failure Flashes Remark

Coolant temperature sensor failure 4 Short

Speed sensor failure 6 Short

Rack position sensor failure 7 Short

Rack actuator failure 8 Short

EGR valve failure 1 Long and 3 Short

CSD solenoid valve failure 1 Long and 4 Short

Main relay failure 1 Long and 6 Short

Rack actuator relay failure 1 Long and 7 Short

ECU temperature alarm 2 Long and 5 Short ECU temp > 221F

Coolant temperature alarm 3 Long and 6 Short Coolant temp > 230F

ECU failure 4 Long and 1 Short

7/51, 7/71, 12/56

57 OPTIONS

LUBRICATOR GENERAL INFORMATION

SAFETY Oil capacity: 2 litres

Oil specification:
Refer to the Tool Manufacturer’s Manual.
WARNING: Ensure that the lubricator filler cap is re−tightened
correctly after replenishing with oil. OPERATING INSTRUCTIONS
COMMISSIONING
WARNING: Do not replenish the lubricator oil, or service the
lubricator without first making sure that the machine is stopped Check the lubricator oil level and fill as necessary.
and the system has been completely relieved of all air pressure
(Refer to STOPPING THE UNIT in the OPERATING PRIOR TO STARTING
INSTRUCTIONS section of this manual).
Check the lubricator oil level and replenish as necessary.
CAUTION: If the nylon tubes to the lubricator are disconnected then
ensure that each tube is re−connected in its original location. MAINTENANCE
Check the lubricator oil level and replenish as necessary.

FAULT FINDING

FAULT CAUSE REMEDY

No oil flow. Incorrect Reverse the nylon tube
connection. connections to the lubricator.

7/51, 7/71, 12/56

 OPTIONS 58
GENERATOR When the switch is moved to Generator position, the machine
control unit SECU will give a signal to the engine to maintain full/rated
(WDG)
speed. At this engine speed the generator will run at its correct speed
SAFETY to maintain rated voltage with rated frequency.

Refer to the SAFETY SECTION in this manual.

GENERAL INFORMATION
Rated output. 4,8 kW @ 0,8 Power factor
(PF) lagging
Rated voltage 110V 1ph or 230V 1ph or
230V 3ph or 400V 3ph +
230V 1ph @
3000 revs min−1
Voltage regulation +/− 6%
Maximum continuous output 6 kVA @ 0,8 PF
Rotor type Brushless
(110/230V 1ph)
Rotor type Rotating armature with
sliprings
(230V 3ph / 400V 3ph +
230V 1ph)
De−rating factors at 0.8 pf continuous load:
Air in temp 20°C Continuous
Air in temp 30°C 5,7 KVA @ 0.8 p.f
continuous
Air in temp 46°C 4,5 KVA @ 0.8 p.f
continuous
De−rating factors for intermittent load:
Air in temp 20−35°C,55 mins/hr @ 0.8, 5 mins off load
Air in temp 35−40°C,50 mins/hr @ 0.8, 10 mins off load
Air in temp 40°C + ,45 mins/hr @ 0.8, 15 mins off load
When the switch is returned back to Compressor position, the
engine will maintain the speed via pressure regulator valve and
pressure transducer according to the air demand.
When connecting electrical equipment to any of the socket outlets,
it is recommended that the appropriate MCB is in the OFF position
before making the connection, switching the MCB to the ON position
immediately prior to using the equipment.
PRIOR TO STARTING (GENERATOR)
(WDG)
If the generator should become exposed or saturated with
moisture/water deposits, it must be safely dried off before attempting
to make any part or conductor electrically live. This should be done by
wiping away excess water, then running the engine with no electrical
loads connected, until the generator is completely dry.
Ensure all persons concerned are suitably competent with electrical
installations.
Ensure that there is a safe working procedure which has been
issued by supervisory personnel, and that it is understood by all
persons concerned with the operation of the generator.
Ensure that the safety procedure to be applied is based on the
appropriate national regulations.

Socket outlets: Ensure that the safety procedure is followed at al times.

110V 1ph & 230V 1ph 1 x 32 amperes
2 x 16 amperes
Ensure that suitable guidance codes are available to indicate safe
230V 3ph 1 x 16 amperes
working practices, and any hazards to avoid.
400V 3ph + 230V 1ph 400V 3ph = 1 x 16 amperes
230V 1ph = 2 x 16 amperes
Before starting the engine and switching in the generator load,
Earth leakage protection is provided by a single residual current
ensure that :−
device. Miniature circuit breakers (MCB) are fitted to provide both
overcurrent and short circuit protection for the generator.
. The system has been inspected and earthed.
Each socket outlet is protected by a spring loaded weather-proof
cover. . No persons are in a hazardous position.

OPERATING INSTRUCTIONS . Any warnings necessary have been suitably displayed (where
A mode selector switch is provided to switch the machine between applicable).
compressor and generator mode.
Ensure compressor / generator mode switch is set to compressor.

CAUTION: Do not start or stop the machine with the

compressor/generator mode switch in the Generator position. Engine
starting/cranking is prevented in this mode − see also “Operating
Instructions − SECU section”.

7/51, 7/71, 12/56

59 OPTIONS

7/51

7/71, 12/56

STARTING THE MACHINE . Open the service valve fully, with no hose connected.

WARNING: Under no circumstances should volatile liquids such

. Complete the starting sequence above.
as Ether be used for starting this machine.

. Close the service valve as soon as the engine runs freely.

CAUTION: Do not start or stop the machine with the
compressor/generator mode switch in the Generator position. Engine
starting/cranking is prevented in this mode − see also “Operating . Do not allow the machine to run for long periods with the service
Instructions − SECU section”. valve open.

All normal starting functions are incorporated in the key operated . Allow the engine to reach its operating temperature. Then press
switch. button A when fitted (Option on 7/51, standard on 7/71, 12/56).

Turn the key switch to position 2 and hold for 15 seconds max to . At this point in the operation of the machine it is safe to apply full load
allow the air inlet heater to reach working temperature. to the engine.

. Turn the key switch to position 3 (engine start position).

NOTE: Wear hearing protection at all times when the engine is started
with the top open and air is flowing from the valve.
. Release to position 2 when the engine starts.

. Release to position 1 when the alternator charge light is

extinguished.

At temperatures below 0C or if there is difficulty starting first time:

7/51, 7/71, 12/56


STOPPING THE MACHINE
. Close the service valve.
. Allow the machine to run unloaded for a short period of time to
reduce the engine temperature.
. Turn the start switch to the 0 (off) position.
NOTE: As soon as the engine stops, the automatic blowdown valve will
relieve all pressure from the system.
If the automatic blowdown valve fails to operate, then pressure must
be relieved from the system by means of the service valve(s).
CAUTION: Never allow the machine to stand idle with pressure in the
system.
EMERGENCY STOPPING
In the event that the unit has to be stopped in an emergency, TURN
THE KEY SWITCH LOCATED ON THE INSTRUMENT PANEL TO
THE 0 (OFF) POSITION.
RE−STARTING AFTER AN EMERGENCY
If the machine has been switched off because of a machine
malfunction, then identify and correct the fault before attempting to
re−start.
If the machine has been switched off for reasons of safety, then
ensure that the machine can be operated safely before re−starting.
Refer to the PRIOR TO STARTING and STARTING THE UNIT
instructions earlier in this section before re−starting the machine.
MONITORING DURING OPERATION
Should any of the safety shut-down conditions occur, the unit will
stop. These are:
. Low engine oil pressure
. High air discharge temperature
. High engine oil temperature.
. Alternator/drive belt failure circuit.
. Low engine fuel level.
OPTIONS 60
CAUTION: To ensure an adequate flow of oil to the compressor at low
temperature, never allow the discharge pressure to fall below 3,5 bar.
DECOMMISSIONING
When the machine is to be permanently decommissioned or
dismantled, it is important to ensure that all hazard risks are either
eliminated or notified to the recipient of the machine. In particular:−
. Do not destroy batteries or components containing asbestos
without containing the materials safely.
. Do not dispose of any pressure vessel that is not clearly marked
with its relevant data plate information or rendered unusable by drilling,
cutting etc.
. Do not allow lubricants or coolants to be released into land surfaces
or drains.
. Do not dispose of a complete machine without documentation
relating to instructions for its use.
MAINTENANCE
General
Ensure all electrical equipment is properly maintained and
controlled.
Ensure all earth connections are secure and regularly maintained.
Earth leakage circuit breaker (ELCB)
The earth leakage circuit breaker must be mechanically tested daily
by pushing the test button with the machine in its no load condition. The
ELCB should trip to the off (down) position.
The earth leakage circuit breaker should also be tested every 3
months. A proprietary test meter should be used to induce live to earth
preset flow at each socket outlet. This current flow will produce the
required earth fault check. The test should be conducted in accordance
with appropriate national standards.
Instruments and controls
A Voltmeter is provided to indicate the output voltage.
Miniature circuit breakers provide over−current protection. In the
event of excess current the appropriate circuit breaker will trip to the
OFF position
.
Note: The current trip rating is quoted at a nominal 40°C ambient
temperature.
An earth leakage circuit breaker provides additional protection in
the event of a leakage to earth in excess of 30 milliamperes on the
connected appliance or in the connections to the generator.
For alternator maintenance refer to Mecc Alte operation and
maintenance manual.
7/51, 7/71, 12/56
61 OPTIONS
FAULT FINDING

FAULT CAUSE REMEDY FAULT CAUSE REMEDY

No output. Load plugs not Ensure that the load plugs are fitted The output Overload Check and reset each circuit
fitted into correctly into the socket outlets. voltage condition. breaker. If the condition persists
socket outlets collapses then investigate the cause and
correctly. when a load rectify the fault as necessary. (see
is also ’Circuit breaker trips’)
No output. Loose Remove end cover and terminal connected
connected.
connection. box lid and check for loose Short circuit. Check for a short circuit and rectify
connections. Rectify the fault as the fault as necessary.
necessary.
Incorrect Check the wiring and rectify the
Faulty rectifier. Check the rectifier bridge which is wiring. fault as necessary.
located inside the rear housing.
Circuit Overload Check and reset each circuit
Faulty Check the capacitors. breaker condition. breaker. If the condition persists
capacitor. trips. then investigate the cause and
rectify the fault as necessary. (see
The No load Check the capacitors and also ’Circuit breaker trips’)
voltage is low associated wiring.
but increases Short circuit. Check for a short circuit and rectify
when a load is the fault as necessary.
applied.
Fault in Check the appliance and rectify the
The No load Check the capacitors and appliance. fault as necessary.
voltage falls associated wiring.
when a load is A circuit Circuit breaker Repair or replace as necessary.
applied. breaker fails latching
to re−set mechanism
Loss of Refer to Mecc Alte maintenance whilst the faulty.
residual manual machine
magnetic field running.
No output. Output Measure the voltage across the
winding(s) winding(s). Replace the generator
damaged. if damaged.
Refer to Engine Manufacturer’s manual and Mecc Alte
Field winding Replace the generator. manufacturer’s manual
damaged.
Generator Engine is not Check the engine speed with a
fails to running at full tachometer. Consult
provide speed. Ingersoll−Rand if the engine is
maximum found to be running slow (Refer to
output. section 4 General Information).
Drive belt is Re−tension the drive belt.
not tensioned
correctly.
Drive pulley is Check the drive pulley and tighten
loose on the as required.
drive shaft.

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 OPTIONS 62
A.C. Electrical Power Schematic Diagram. 115V 1 − phase.

KEY

CB1 Circuit breaker R Resistor

63A
SK1 Socket outlet 32A
CB2 Circuit breaker
SK2 Socket outlet 16A
32A
SK3 Socket outlet 16A
CB3 Circuit breaker
16A SV3 Switch, generator
CB4 Circuit breaker V Voltmeter
16A
VF1 Fuse
G Alternator Voltmeter
K1 Contactor VF2 Fuse
Voltmeter
PB Pushbutton
PE Protective earth conductor

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63 OPTIONS

A.C. Electrical Power Schematic Diagram. 230V 1 − phase.

KEY

CB1 Circuit breaker R Resistor

32A
SK1 Socket outlet 32A
CB2 Circuit breaker
SK2 Socket outlet 16A
16A
SK3 Socket outlet 16A
CB3 Circuit breaker
16A SV3 Switch, generator
G Alternator V Voltmeter
K1 Contactor VF1 Fuse
Voltmeter
PB Pushbutton
VF2 Fuse
PE Protective earth conductor
Voltmeter

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 OPTIONS 64
A.C. Electrical Power Schematic Diagram. 400/230V 3 − phase.

KEY

CB1 Circuit breaker R1 Resistor

16A
SK1 Socket outlet 16A
CB2 Circuit breaker
SK2 Socket outlet 16A
10A
SK3 Socket outlet 16A
CB3 Circuit breaker
10A SV3 Switch, generator
G Alternator V Voltmeter
K1 Contactor VF1 Fuse
Voltmeter
PB Pushbutton
VF2 Fuse
PE Protective earth conductor
Voltmeter
R Resistor

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65 ENGINE INSTRUCTION MANUAL

4IRI8NE−2 / 4IRI8TE
ENGINES

CONTENTS

66 FOREWORD
67 EXTERNAL VIEW :
4IRI8NE−2 / 4IRI8TE
68 GENERAL INFORMATION:
4IRI8NE−2 / 4IRI8TE
Main data and specifications
Engine identification
Portable Power engine after sales support
EMISSION CONTROL LABEL
70 FUEL, LUBRICANT, AND COOLANT
Fuel
Lubricant
Coolant
72 OPERATION
Check before operation
Check and operation after start− up
Operation and care of a new engine
75 PERIODICAL INSPECTION
AND MAINTENANCE
Lubricating system
Cooling system
Fuel system
Air intake system
Routine maintenance
79 TROUBLESHOOTING

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 FOREWORD 66
ENGINE − General Information
The Portable Power industrial diesel engines are a product of long years of experience, advanced technology, and up−to date production facilities.
Portable Power takes great pride in the superior durability and operating economy of these engines.
In order to get the fullest use and benefit from your engine, it is important that you operate and maintain it correctly. This Manual is designed to help
you do this.
Please read this Manual carefully and follow its operating and maintenance recommendations. This will ensure many years of trouble−free and
economical engine operation.
Should your engine require servicing, please contact your nearest Portable Power branch or distributor.
All information, illustrations, and specifications contained in this Manual are based on the latest product information available at the time of
publication.
Portable Power reserves the right to make changes in this Manual at any time without prior notice.

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67 EXTERNAL VIEWS

DIESEL ENGINE Engine External View − Model

1. Lifting eye (Flywheel end) 15.Intake manifold

2. Turbocharger 16.Fuel filter
3. Lifting eye (Engine cooling fan end) 17.Fuel oil inlet
4. Engine coolant pump 18.Fuel return to fuel tank
5. Cooling fan 19.Filler port (Engine oil)
6. Crank shaft V−pulley 20.Rocker arm cover
7. V−belt 21.Air intake port (From air cleaner)
8. Filler port (engine oil) 22.Flywheel
9. Drain plug (engine oil) 23.Starter motor
10.Fuel injection pump 24.Exhaust manifold
11.Engine oil cooler 25.Alternator
12.Engine oil filter 26.EGR valve
13.Dipstick (engine oil) 27.EGR cooler
14.Eco−governor 28.EGR pipe

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 GENERAL INFORMATION 68

EPA CERTIFIED ENGINE DATA and SPECIFICATIONS

Model: 4IRI8NE−2 / 4IRI8TE

Engine model name 4IRI8NE−2 / 4IRI8TE

Engine type Vertical inline water cooled diesel engine
Combustion type Direct injection
Aspiration Natural / Turbocharged
No. of cylinders − bore x stroke. mm 4−98x110
Engine displacement L 3.319
Compression ratio 18.5:1 / 18.1:1
Firing order 1 −3 − 4 − 2
Exhaust emission control system Fuel injection nozzles, fuel injector pump
Governor Electronic
Specified fuel Diesel fuel (ISO 8217 DMX, BS2869 A1/A2)
No. 2−3, No. 1−D, ASTM D975−94
Starter (V−kW) 12−2.3
Alternator (V−A) 12−40
Specified engine oil (API grade) (SAE grade) CI−4+ (15W40)
Coolant volume (Engine only) L 4.2
Engine dry weight kg 235 / 245
Overall length mm 719
Engine dimensions Overall width mm 508
Overall height mm 717
Nozzle injection pressure MPa 21.6

ENGINE IDENTIFICATION ENGINE AFTER SERVICE

Serial No Location Contact your Portable Power dealer for periodical inspection and
maintenance.
The engine serial number is stamped on engine name plate on top of
rocker cover. Portable Power parts are identical with those used in the engine
production, and accordingly, they are warranted by Portable Power.
Confirmation of Engine Number Genuine Ingersoll−Rand parts are supplied by your Portable Power
It is advisable to quote the engine serial number together with the branch or distributor.
machine serial number, as it is required when you contact the
Please ensure that only genuine Ingersoll−Rand parts, lubricants and
Portable Power branch or distributor for repair, service or parts
fluids are used for service and/or repair.
ordering.
CAUTION: Conduct confirmation of engine serial number with the
engine stopped. To avoid being injured, do not check it, while the engine
is still hot.

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69 EMISSION CONTROL LABEL

ENGINE LABEL (FOR EPA)

Emission control label is attached on the “top of rocker arm cover.”

The location of emission control label attached on the engine may vary depending on the engine specification

The following is the sample of a label required for engine emission control information, along with location.
 FUEL, LUBRICANTS, AND COOLANT
FUEL
Fuel Selection
The following properties are required of the diesel fuel.
Must have high cetane value., (45 or greater)
The sulfur content must not exceed 0.5% by volume. A higher sulfur
content fuel may cause sulfuric acid corrosion in the cylinders of the
engines.
NEVER mix kerosene, used engine oil, or residual fuels with the
diesel fuel.
Water and sediment in the fuel should not exceed 0.05% by volume.
Keep the fuel tank and fuel−handling equipment clean at all times.
Poor quality fuel can reduce engine performance and/or cause
engine damage.
Fuel additives are not recommended. Some fuel additives may
cause poor engine performance. Consult your Portable Power
representative for more information.
Ash content not to exceed 0.01% by volume.
Carbon residue content not to exceed 0.35% by volume. Less than
0.1% is preferred.
Total aromatics content should not exceed 35% by volume. less
than 30% is preferred.
PAH (polycyclic aromatic hydrocarbons) content should be below
10% by volume.
Metal content of Na, Mg, Si, and AI should be equal to or lower than
1 mass ppm. (Test analysis method JPI−5S−44−95).
Lubricity: Wear mark of WS1.4 should be Max. 01018 in (460 um) at
HFRR test.
Diesel fuel should comply with the specifications listed in the table
below. The table lists several worldwide specifications for diesel fuels.
Diesel Fuel Specification Location
No. 2−D, No. 1−D, ASTM D975−94 USA
EN590:96 European Union
ISO 8217 DMX International
BS (BRITISH STANDARD) BS2869−A1 or A2 United Kingdom
JIS K2204 Grade No. 2 Japan
KSM−2610 Korea
GB252 China
FUEL REQUIREMENTS
Notice: the fuel injection pump, injector or other parts of the fuel system
and engine can be damaged if you use any fuel or fuel additive other
than those specifically recommended by Portable Power.
NOTE: If any fuel other than the one specified is used, engine operation
will be impaired. Engine failure or malfunction resulting from use of such
improper fuel will not be warranted by Portable Power.
To help avoid fuel system or engine damage, please read the following:
Do not use diesel fuel which has been contaminated with engine oil.
Besides causing engine damage, such fuel can also affect emission
control. Before using any diesel fuel, check with the fuel supplier to see
if the fuel has been mixed with engine oil.
70
Your engine is designed to use either Number 1−D or Number 2−D
diesel fuel. However, for better fuel economy, use Number 2−D diesel
fuel whenever possible. At temperatures less than −7C, (20F),
Number 2−D fuel may pose operating problems (see “Cold Weather
Operation” which follows). At colder temperatures, use Number 1−D
fuel (if available) or use a “winterized” Number 2−D (a blend of Number
1−D and Number 2−D). This blended fuel is usually called Number 2−D
also, but can be used in colder temperatures than Number 2−D fuel
which has not been “winterized.”
Check with the fuel supplier to be sure you get the properly blended
fuel.
NOTICE: Do not use home heating oil or gasoline in your diesel
engine; either may cause engine damage.
Handling of the Fuel.
Any fuel containing dust particles or water might cause engine
failure.
Therefore, the following must be observed.
Take care to protect the fuel from ingress of dust particles or water
when filling the fuel tank.
If refueling is done from an oil drum directly, ensure that it has been
kept stationary to allow any dust, sediment or water to settle at the
bottom. Do not draw fuel direct from the bottom of the drum to prevent
pickup of any settled foreign material.
Always fully fill the fuel tank. Drain the sedimented particles in the
fuel tank frequently.
Water in Fuel
During refueling, it is possible for water (and other contaminants) to be
pumped into your fuel tank along with the diesel fuel. This can happen
if a fuel provider does not regularly inspect and clean its fuel tanks, or
receives contaminated fuel from its supplier(s). To protect your engine
from contaminated fuel, there is a fuel filter system on the engine which
allows you to drain excess water.
CAUTION: The water/diesel fuel mixture is flammable, and could be
hot. To avoid personal injury and/or property damage, do not touch the
fuel coming from the drain valve, and do not expose the fuel to open
flames or sparks.
Be sure you do not overfill the fuel tank. Heat (such as from the engine)
can cause the fuel to expand. If the tank is too full, fuel could be forced
out. This could lead to a fire and the risk of personal injury and/or
equipment damage.
Biocides
In warm or humid weather, fungus and/or bacteria may form in diesel
fuel if there is water in the fuel.
NOTICE: Fungus or bacteria can cause fuel system damage by
plugging the fuel lines, fuel filters or injector. They can also cause fuel
system corrosion.
If fungus or bacteria has caused fuel system problems, you should
have your authorized dealer correct these problems. Then, use a diesel
fuel biocide to sterilize the fuel system (follow the biocide
manufacturer‘s instructions). Biocides are available from your dealer,
service stations, parts stores and other automotive places. See your
authorized dealer for advice on using biocides in your area and for
recommendations on which biocides you should use.
Smoke Suppressants
The use of a smoke suppressant additive is not allowed because of the
greater possibility of stuck rings and valve failure, resulting from
excessive ash deposits.
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71 FUEL, LUBRICANTS, AND COOLANT

LUBRICANT. NOTE

The quality of engine oil can affect engine performance, startability
and engine life.
Use of unsuitable engine oil will result in piston ring, piston and
cylinder seizure and accelerate surface wear causing increased oil
consumption, lowered output and, finally engine failure. To avoid this,
use the specified engine oil.
1) Engine Oil Selection
Using a mixture of different brands or quality of oils will adversely affect
the original oil quality; therefore, never mix different brand or different
type oils.
Do not use API, CA, CB grade and reconstituted engine oil
Engine damage due to improper maintenance, or using oil of the
improper quality and/or viscosity, is not covered by the warranty.

Pro Tec

2) Oil Viscosity
Engine oil viscosity affects engine startability, performance, oil
consumption, wear and the potential for seizure, etc. Always ensure
that lubricants with the correct viscosity for the operating temperature
are used. Refer to fig 12.

Fig. 12

A. (Single − grade) IMPORTANT:

B. Ambient Temperature • Be sure to add Long Life Coolant Antifreeze (LLC) to soft water. In
cold season, the LLC is especially important. Without LLC, cooling
C. (Multi − grade) performance will decrease due to scale and rust in the cooling water
line. Without LLC, cooling water will freeze and expand to break the
cooling line.
COOLANT
• Be sure to use the mixing ratios specified by the LLC manufacturer
All Portable Power compressor engines are factory filled with a for your temperature range.
50/50 Ethylene glycol base antifreeze/water mix. which provides
protection to −33C (−27F) • Do not mix different types (brand) of LLC, chemical reactions may
make the LLC useless and engine trouble could result
• Replace the cooling water every once a year

CAUTION:
When handling Long Life Coolant Antifreeze, wear protective
rubber gloves not to contact with it. If contact with the eyes or skin
should occur, wash with clean water

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ENGINE OPERATION
Engine Exhaust Gas Caution (Carbon Monoxide)
CAUTION
Do not breathe exhaust gas because it contains carbon monoxide,
which by itself has no color or odor. Carbon monoxide is a dangerous
gas. It can cause unconsciousness and can be lethal.
Do not run the engine in confined areas (such as garages or next to a
building). Keep the exhaust tailpipe area clear of snow and other
material to help reduce the buildup of exhaust gases under the
equipment. This is particularly important when parked in blizzard
conditions.
CHECK BEFORE OPERATION
CAUTION: For safety reasons, conduct the inspection with the engine
stopped.
Engine Oil Level.
Place the engine or the machine on a level surface
Remove the dipstick, wipe it with a cloth. Insert it fully and take it out
gently again.
Check the oil level against the marks on the dipstick. The oil level
must be between the upper level mark and the lower level mark as
illustrated.
OPERATION 72
Remove filler cap (yellow coloured) on the rocker arm cover side of
engine.
Fill with engine oil up to the upper limit on the dipstick.
Manually tighten the filler cap.
Do not use a tool such as pliers to tighten it.
Engine oil pan capacity (oil pan) (L) − 10.2 (10.8 quarts).
A certain period of time is required before the engine oil completely
flows down from the oil filler to the crankcase. Wait at least ten minutes
before checking the oil level.
NOTE: Take care to avoid engine oil being splashed on the fan drive
belt because it causes belt slippage or slackness.
CAUTION: When adding oil, take care not to spill it. If you spill oil on
the engine or equipment, wipe it properly, to prevent the risk of fire and
personal injury and/or equipment damage.
Fan Belt Check
Check the fan belt for tension and abnormalities.
When the belt is depressed 7 − 10 mm with the thumb (about 100N
[10 kg] pressure) midway between the fan pulley and alternator pulley,
the belt tension is correct.
If the belt tension is too high, it will result in alternator failure.
A loose belt will cause belt slippage which may result in a damaged
belt, abnormal noise, poor battery charging and engine overheating.

Fig. 16

Coolant Level Check

The coolant level must be between “MAX COLD” and “MIN” marks on
the reserve tank depending on the temperature of the engine. Check
and ensure that the level is correct.

CAUTION: When removing the radiator filler cap, while the engine is
still hot, cover the cap with cloth, then turn it slowly to gradually release
the internal steam pressure. this will prevent anyone from being
scalded by hot steam spurting out from the filler neck.

Add coolant mixed to the correct ratio: 50/50 ethylene glycol/water.

Radiator Cap Condition

After the replenishment of the coolant, install the radiator filler cap.
Make sure the cap is securely installed.

A. Filler cap
B. Filler port (engine oil) Battery Cable Connection

C. Dipstick Check the battery cable connections for looseness or corrosion. A

loosened cable connection will result in hard engine starting or
D. Upper limit insufficient battery charge. The battery cables must be tightened
securely. Never reverse “+” and “−” terminals when reconnecting
E. Lower limit cables after disconnection. Even a short period of reverse connection
F. Dipstick will damage the electrical parts.

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73 OPERATION
Fig. 17
A Battery cable
B Connections
Battery Electrolyte level
The amount of electrolyte in the batteries will be reduced after repeated
discharge and recharge. Check the electrolyte level in the batteries,
replenish with a commercially available electrolyte such as distilled
water, if necessary. The battery electrolyte level checking procedure
will vary with battery type. NOTICE: Do not replenish with dilute sulfuric
acid in the daily service.
CAUTION:
When inspecting the batteries, be sure to stop the engine first.
As dilute sulphuric acid is used as electrolyte, be careful not to
contaminate your eyes, hands, clothes, and metals with the electrolyte.
If it gets in your eye, wash with a large amount of water at once, then
seek medical advice.
As highly flammable hydrogen gas is released from the batteries, do not
create a spark or allow any naked flame near the batteries.
When handling such metallic articles as tools near the batteries, be
sure not to contact the “+” terminal because the compressor body is “−”
and a dangerous short circuit might result.
When disconnecting the terminals, start with “−” terminal. When
connecting them, connect the “−” terminal last.
Fuel level
Check the remaining fuel oil level in the fuel tank and re−fuel if
necessary.
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CHECKS AND OPERATION AFTER START−UP
Check after the Engine Start−up
Check the following items in the engine warming−up operation.
Engine noise and exhaust smoke color −
Listen to the engine and, if any abnormal noise is heard, check to
determine the cause.
Check the fuel combustion condition by observing the exhaust
smoke color. The exhaust smoke color after engine warm−up and at
no−load condition should be colorless or light blue.
Black or white smoke indicates incorrect combustion.
Note: After start−up from cold the engine might be noisier and the
exhaust smoke color darker than when it has warmed up. However this
condition will disappear after warm up.
Leakage in the systems −
Check the following items:
Lubrication oil leakage −
Check the engine for oil leaks, paying particular attention to oil filter
and oil pipe joints.
Fuel leakage −
Check the fuel injection pump, fuel lines and fuel filter for leakage.
Coolant leakage −
Check the radiator and water pump hose connections and the water
drain cock on the cylinder block for leakage.
Exhaust smoke or gas leakage.
Checking coolant level
The coolant level could drop because any mixed air is expelled in about
5 minutes after the engine started.
Stop the engine, remove radiator cap, and add coolant.
CAUTION: Hot steam can rush out and you could get burnt if the
radiator cap is removed when the engine is hot. Cover the radiator cap
with a thick cloth and loosen the cap slowly to reduce the pressure, then
remove the cap.

OPERATION AND CARE OF A NEW ENGINE
Your Portable Power engine is carefully tested and adjusted in the
factory, however, further run−in is necessary. Avoid any harsh engine
operation within the initial 100 operating hours.
Do not operate the unit at full load until the engine is warmed−up.
Do not allow the engine to run unloaded for extended periods so as to
minimise the risk of cylinder bore glazing.
During operation, pay attention to the following points if the engine
shows any sign of abnormalities.
(1) Engine Oil Pressure − The engine oil pressure is monitored by a
switch that will stop the engine if the pressure falls below a pre−set
value.
(2) Coolant Temperature − The engine performance will be adversely
affected if engine coolant temperature is too hot or too cold. The normal
coolant temperature is 75 to 85C (167 to 185F).
Overheating
CAUTION:
If you see or hear escaping steam or have other reason to suspect
there is a serious overheat condition, stop the engine immediately.
If the Engine Coolant Temperature gage (where fitted) shows an
overheat condition, or you have reason to suspect the engine may be
overheating, take the following steps:
 Close the service valve to reduce the load.
 Let the engine run at normal idle speed for two or three minutes. If
the engine coolant temperature does not start to drop, turn off the
engine and proceed as follows:
CAUTION: To help avoid being burned −
 Do not open the canopy or door if you see or hear steam or engine
coolant escaping. Wait until no steam or engine coolant can be seen or
heard before opening the engine canopy or door.
 Do not remove the radiator filler cap if the engine coolant in the
reserve tank is boiling. Also do not remove the radiator filler cap while
the engine and radiator are still hot. Scalding fluid and steam can be
blown out under pressure if either cap is taken off too soon.
If no steam or engine coolant can be seen or heard, open the canopy
or door. If the engine coolant is boiling, wait until it stops before
proceeding. The engine coolant level should be between the “MAX
COLD” and “MIN” marks on the reserve tank.
OPERATION 74
Make sure the fan belt is not broken, or off the pulley, and that the fan
turns when the engine is started. If the engine coolant level in the
reserve tank is low, look for leaks at the radiator hoses and
connections, radiator, and water pump. If you find major leaks, do not
run the engine until these problems have been corrected. If you do not
find a leak or other problem, WAIT UNTIL THE ENGINE HAS COOLED
DOWN then carefully add engine coolant to the reserve tank.
(Engine coolant is a mixture of ethylene glycol antifreeze and water.
See “Engine Care in cold season” for the proper antifreeze and
mixture.)
CAUTION: To avoid being burned, do not spill antifreeze or engine
coolant on the exhaust system or hot engine parts. Under some
conditions the ethylene glycol in engine coolant is combustible.
If the engine coolant level in the reserve tank is at the correct level but
there is still an indication of an overheat condition and no cause was
found, please consult your local branch or dealer.
Overcooling
Operating the engine at low coolant temperature will not only increase
the oil and fuel consumption but also will lead to premature parts wear
which may result in engine failure. Ensure that the engine reaches
normal operating temperature 75 to 85C (167 to 185F) within ten
minutes of starting.
(3) Hourmeter
This meter indicates the machine operation hours. Make sure that the
meter is always working during engine operation. Periodical machine
maintenance is scheduled on the operation hours indicated on the
hourmeter.
(4) Liquid and Exhaust Smoke Leakage
Make regular checks for lubricant, fuel, coolant and exhaust smoke
leakage.
(5) Abnormal Engine Noise
In the event of any abnormal engine noise, please consult your local
branch or dealer.
(6) State of the Exhaust Smoke
Check for any abnormal exhaust smoke color.
ENGINE STOPPING
(1) Close service valves.
(2) Before stopping the engine, cool down the engine by operating it at
reduced load about three minutes. In this period, check the engine
noise for abnormalities.
LONG TERM STORAGE
If the equipment is to be out of operation for an extended period, it
should be started at least once per week and run on load for about 15
minutes after it has reached normal operating temperature.
If this is not possible,
 Do not drain the cooling water
 Clean dust or oil from the engine extension
 Either fill completely or drain the fuel tank
 Grease accelerator joints and electrical connections
 Disconnect the negative battery terminal
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75 PERIODICAL INSPECTION AND MAINTENANCE.

ENGINE MAINTENANCE

Inspection after initial 50 hours operation

(1) Replacing the engine oil and engine oil filter (1st time)
When the engine oil is still hot, be careful with a splash of engine oil
which may cause burns. Cool the engine to replace engine oil until the
engine oil becomes warm. It is most effective to drain the engine oil
while the engine is still warm.
In early period of use, the engine oil gets dirty rapidly because of the
initial wear of internal parts. Replace the engine oil earlier.
Engine oil filter should also, be replaced when the engine oil is replaced.
Engine oil and engine oil filter replacing procedures are as follows.
Remove the oil filler cap to drain easily while draining the engine oil.

1) Prepare a waste oil container collecting waste oil.

2) Loosen the drain plug using a wrench (customer procured) to drain
the engine oil.
3) Securely tighten the drain plug after draining the engine oil.
4) Turn the engine oil filter counter−clockwise using a filter wrench
(customer procured) to remove It.
5) Clean the engine oil filter mounting face. The location depends on the engine installed on the machine unit
6) Moisten the new engine oil filter gasket with the engine oil and install A. Dipstick
the new engine oil filter manually turning it clockwise until it comes into
contact with the mounting surface, and tighten it further to 3/4 of a turn B. Oil pan
with the filter wrench.
C. Drain plug
Tightening torque: 19.623.5Nm (2.02.4kgfm)

Applicable engine oil filter Part No. CCN 22226351

7) Fill with the new engine oil until it reaches the specified level as
explained in OPERATION section.
8) Warm up the engine by running for 5 minutes while checking any oil
leakage.
9) Stop the engine after warming up and leave it stopping for about 10
minutes to recheck the engine oil level with dipstick and replenish the
engine oil. If any oil is spilled, wipe it away with a clean cloth.
10)Resume engine oil and filter changes at 250 our intervals (with non
IR fluids) or 500 hour intervals with Ingersoll Rand Protec
engine fluid
and filters.

NOTE: The use of genuine Ingersoll Rand oil and filters will qualify for
extended warranty coverage. Refer to Warranty Section of the manual.

Ingersoll Rand Protec
Engine Fluid Part No. 54480918 (1 gallon).

A. Engine oil filter

IMPORTANT: B. Loosen
Do not overfill the oil pan with engine oil. Be sure to keep the specified
level between upper and lower limit on the dipstick. C. Tighten

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 PERIODICAL INSPECTION AND MAINTENANCE.
(2) Draining Water from Fuel Filter/separator.
The fuel filter/separator is provided to allow water to be drained from the
fuel system. Water is heavier than fuel so any water contained in the
system will collect in the bottom of the bowl.
The clear bowl ‘D’ should be checked on a daily basis and if water is
present, it should be drained from the separator.
Place a suitable container under the separator to prevent any spillage
inside the machine.
Slacken the drain valve ‘E’ until water drains from the vent tube.
When all the water has been evacuated, tighten the drain valve ‘E’ and
follow the “fuel system air bleeding” procedure below.
(3) Fuel System Air Bleeding
The entry of air into the fuel system will cause difficult engine starting
or engine malfunction.
When carrying out service procedures such as emptying the fuel tank,
draining the filter/separator, and changing the fuel filter element be sure
to bleed air from the fuel system.
To activate the “automatic air−bleeding system”, turn the key switch to
the “ON” position and energize the electromagnetic pump” to bleed the
air.
Air bleeding method:
When the “starter switch” is set to the “ON” position to activate the
electromagnetic pump, fuel is forced to the fuel valve of each injection
pump and then to the leak−off pipe of each injector nozzle, so that any
air in the fuel system bleeds off automatically to the fuel tank.
NOTE:
Although the fuel system can bleed air automatically when the key
switch is in the “ON” position, air can also be manually bled by use of
the primer pump facility in the filter/separator assembly.
By unscrewing the plastic primer pump head ‘A’ and stroking it up and
down, any air bubbles in the system will be purged back to the fuel tank.
When this has been completed, the pump head must be screwed back
into the filter/separator assembly.
Start the engine and visually check the fuel system for leaks.
76
(4) Replacing fuel filter
Replace the fuel filter at specified intervals before it is clogged with dust
to adversely affect the fuel flow. Also, replace the fuel filter after the
engine has fully been cooled.
1) Remove the fuel filter using a filter wrench (customer procured).
When removing the fuel filter, hold the bottom of the fuel filter with a
piece of rag to prevent the fuel oil from dropping. If you spill fuel, wipe
such spillage carefully.
2) Clean the filter mounting surface and slightly apply fuel oil to the
gasket of the new fuel filter.
3) Install the: new fuel filter manually turning until it comes into contact
with the mounting surface, and tighten it further to 1/2 at a turn, using
a filter wrench. Tightening torque: 11.815.6Nm(1.21.6kgfm).
Applicable fuel filter Part No. CPN 16539462
4) Bleed the fuel system. Refer to Inspection at 50 hours.
IMPORTANT:
Be sure to use genuine IR part (super fine mesh filter). Otherwise, it
results in engine damage, uneven engine performance and shorter
engine life.
(4) Changing oil/water separator element.
NOTE:
The cartridge and bowl contain fuel. Take care not to spill it during
disassembly and reassembly.
The fuel filter/separator also provides primary filtration and the element
‘C’ should be changed every 500 operating hours or 6 months,
whichever comes first.
Change procedure:
Unscrew the element ‘C’ from the head taking care not to spill fuel inside
the machine. Drain any fuel within into a suitable container, then
unscrew the clear bowl ‘D’ from the element.
Discard the old element into a suitable container.
Remove the old ‘O’ ring from the bowl ‘D’ and install the new one
supplied with the element. Apply a light coat of clean engine oil to the
‘O’ ring and screw the bowl ‘D’ onto the new element ‘C’.
Using a clean cloth, wipe the sealing face of the filter/separator head
to ensure correct seating of the sealing ring.
Fill the element/bowl assembly with clean fuel oil then apply a light coat
of clean engine oil to the new element seal ring.
Screw the new element onto the head firmly by hand.
Follow the “fuel system air bleeding” procedure.
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77 PERIODICAL INSPECTION AND MAINTENANCE.
Inspection every 1000 hours operation
(1) Replacing cooling water
Cooling water contaminated with rust or water scale −reduces the
cooling effect. Even when antifreeze agent (LLC) is mixed, the cooling
water gets contaminated due to deteriorated ingredients. Replace the
cooling water at least Once a year.
1) Remove the header tank cap.
2) Remove the bottom radiator hose of the radiator and drain the
cooling water.
3) After draining the cooling water, reconnect the hose.
4) Fill radiator and engine with cooling water via the header tank.
CAUTION:
Wait until the temperature goes down before draining the Cooling
water. Otherwise, hot water may splash to cause scalding.
(2) Adjusting intake / exhaust valve clearance
As this adjustment requires specialized knowledge and skill, consult
your Portable Power dealer. The adjustment is necessary to maintain
the correct timing for the opening and closing of valves. Neglecting the
adjustment will cause the engine to run noisily and result in poor engine
performance and other damage.
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Inspection every 1500 hours operation
(1) Inspect, Clean and Test Fuel Injectors
As the adjustment requires specialized knowledge and skill, consult
your Portable Power dealer. This adjustment is needed to obtain the
optimum injection pattern for full engine performance.
(2) Inspect Turbocharger (Blower Wash as Necessary)
Turbo charger service is required by the EPA/ARB every 1500 hours.
Your authorized Portable Power dealer or distributor will inspect and
blower wash the unit if necessary.
(3) Inspect, Clean and Test EGR Valve
The EGR valve is a key component for cleaning exhaust gas.
To prevent the valve from deteriorating in exhaust gas recirculation
performance due to carbon accumulation, inspect, clean and test the
valve at least every 1500 hours. Consult your local Portable Power
dealer for this service.
(4) Inspect and Clean EGR Lead Valve
The EGR lead valve is located in the passage of recirculated gas.
To prevent carbon accumulation in or clogging of the lead valve, inspect
and clean the lead valve at regular intervals. Consult your local
Portable Power dealer for this service.
(5) Clean EGR Cooler
The EGR cooler is apt to be contaminated with rust and scale that
deteriorate the cooling performance. Carbon accumulation in the
exhaust gas passage of the cooler hinders circulation of exhaust gas,
resulting in deterioration in exhaust gas cleanup performance.
To prevent such a problem, clean the cooler at least every 1500 hours.
Consult your local Portable Power dealer for this service.
EGR cooler
EGR valve
EGR lead valve
(6) Inspect Crankcase Breather System
Proper operation of the crankcase breather system is required to
maintain the emission requirements of the engine. The EPA/ARB
requires that you have the crankcase breather system inspected every
1500 hours. See your authorized Portable Power dealer or distributor
for this service.
 PERIODICAL INSPECTION AND MAINTENANCE. 78
Inspection every 2000 hours operation Diagnosis Tool

(1) Flushing the cooling system and checking the cooling A connector is provided at an end of the harness of the driven machine
system parts so that the diagnosis tool can be loaded with data from the E−ECU.

As this maintenance requires specialized knowledge and skill, consult
your Portable Power dealer. Rust and water scale will accumulate in the
cooling system through many hours of operation. This lowers the
engine cooling effect.
(2) Checking and replacing fuel hoses and cooling water hoses
As this maintenance requires specialized knowledge and skill, consult
your Portable Power dealer. Regularly check the rubber hoses of the
fuel system and cooling water system. If cracked or degraded, replace
them with new one. Replace the rubber hoses at least every 2 years.
When the fuel injection pump is replaced, data in the E−ECU must also
be replaced for accomodating the new pump. When the EECU is
replaced, the fuel injection data in the existing unit must be migrated to
the new unit. The diagnosis tool can be used for the data replacement
or migration. Contact your local Portable Power dealer for replacement
of the fuel injection pump or E−ECU.
Diagnosis Tool
(Yanmar genuine)

(3) Lapping the intake and exhaust valves

As this maintenance requires specialized knowledge and skill, consult
your Portable Power dealer. The adjustment is necessary to maintain
proper contact of the valves and seats.
(4) Checking and adjusting the fuel injection timing
As this maintenance requires specialized knowledge and skill, consult
your Portable Power dealer.
Communication
(5) Checking and adjusting the EPA emission related parts. adaptor
The inspection and servicing require specialized knowledge and
techniques. Consult your Portable Power dealer or distributor.
EPA allows to apply maintenance schedule for emission related parts
as follow.

Battery 12V

Mating connector (Tool side)

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79 ENGINE TROUBLESHOOTING

This item contains a simple troubleshooting. When a failure takes place on your Portable Power engine, diagnose the cause referring this
troubleshooting. Should the cause of failure not be detected or you are unable to manage the failure, consult your machine supply source or nearest
Portable Power engine service outlet.

Engine does not start Battery discharged

Starter does not turn. Bad cable connections.

Starter or starter switch failure.

Safety relay failure.

No fuel in the fuel tank.

No fuel injection. Clogged fuel filter element.

Air in the fuel system.

Starter turns but engine does not Control rack is stuck at no fuel
fire. position.

Incorrect preheating operation.

Fuel is injected but engine does not Faulty air heater.

fire.

Incorrect injection timing.

Low cylinder compression

pressure.

Engine fires but stalls immediately. Air in the fuel system.

A connector is provided at an end of the harness of the driven machine

so that the diagnosis tool can be loaded with data from the E−ECU.

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 ENGINE TROUBLESHOOTING 80
Unstable engine running Crack in injection pipe.

Unstable low idling Injection nozzle failure.

Uneven compression pressure between cylinders.

Incorrect high idle speed Software/Electronic malfunction.

adjustment.

Engine hunting in medium speed Software/Electronic malfunction.

range.

Air in the fuel system

Insufficient fuel supply. Clogged fuel filter element

Piping failure (squeezed/restricted

etc.)

Engine malfunction in high speed Uneven fuel injection amount between cylinders.
range.

Incorrect valve clearance adjustment.

Deteriorated valve spring.

Engine speed stuck at high idle. Engine control restriction or seizure.

Engine overheat. Insufficient coolant volume.

Fan belt slippage.

Cooling system defect Thermostat malfunction.

Radiator filler cap malfunction.

Cooling system interior fouled.

Radiator clogged.

Engine over−loaded.

Improper servicing Air cleaner element clogged.

Insufficient airflow/restriction.

Restricted coolant flow (high concentration of antifreeze, etc.)

Low oil pressure Lack of oil Oil leakage

High oil consumption

Wrong oil Wrong type and viscosity.

High coolant temperature. Over heat.

Clogged filter and strainer. Clean and/or replace.

Worn bearings and oil pump. Replace.

Faulty relief valve. Replace.

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81 ENGINE TROUBLESHOOTING

Low engine output Incorrect injection timing Too far advanced.

Too far retarded.

Injection nozzle malfunction Incorrect injection pressure.

Incorrect spray condition.

Incorrect injection pump adjustment Lack of fuel in tank.

Insufficient fuel supply to the Air in injection pump.

injection pump

Fuel filter clogged.

Overflow valve malfunction.

Governor malfunction Incorrect engine control

adjustment.

Deteriorated governor spring.

Incorrect valve clearance

adjustment.

Cylinder compression leakage Injector nozzle misalignment.

Low cylinder compression pressure Cylinder bore wear.

Insufficient air intake volume. Air cleaner clogged.

Restricted air flow.

Excessive oil consumption Incorrect oil Wrong selection of type and viscosity.

Too much oil quantity.

Engine burning oil Faulty piston rings/damaged cylinder bores.

Faulty valve stem seal.

Damaged seal / Damaged turbocharger seal

Oil leakage Loose joints/gaskets.

Improper installation of filter and piping.

Fuel leakage Damaged seals.

Excessive fuel consumption Improper component installation or tightening.

Excessive injection volume. Injection pump defective.

Excessive mechanical loads

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 ENGINE TROUBLESHOOTING 82
Improper exhaust Clogged air cleaner.

Damaged injector nozzle.

Excessive black smoke Faulty EGR Valve

Injection timing incorrect.

Excessive injection volume.

Incorrect fuel.

Water mixing in fuel

Excessive white smoke Low compression pressure.

Injection timing incorrect.

Low coolant temperature

Faulty turbocharger

Battery over discharge Low electrolyte level Crack in battery body.

Natural consumption.

Charging failure Loose or damaged belt.

Faulty alternator.

Damaged wiring or contact failure.

Excessive electrical loads Insufficient battery capacity for the application.

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